cei jacketed firebox heater operation, service & parts manual · honeywell udc1200 modulating...

CEI Jacketed Firebox HeaterOperation, Service & Parts Manual

Heater models 1200 ~ 6300

CEI EnterprisesAlbuquerque, New Mexico, U.S.A.

JacketedFireboxHeaters

Contents

Section 1: Introduction ..................................................... 1SAFETY ..................................................................................... 3

IF YOU SMELL GAS ......................................................................3WARNING! .....................................................................................3IMPORTANT PRECAUTIONS .......................................................3Identification of safety symbols used in this document ..................4

Overview .................................................................................... 5Main Components ...................................................................... 6

Burner.............................................................................................6Jacketed Firebox ............................................................................6Heat Exchanger..............................................................................6Expansion Tank..............................................................................7Other Components .........................................................................7

How it Operates.......................................................................... 8

Section 2: Installation ..................................................... 11Inspection................................................................................. 13Position..................................................................................... 13Connect Electrical .................................................................... 13Add Heat Transfer Fluid ........................................................... 15

Natural Gas / Propane..................................................................18Fuel Oil .........................................................................................19

Initial Startup ............................................................................ 20

Section 3: Operation ...................................................... 21Daily Start Up ........................................................................... 23

Preparation for Start Up - All Fuels ..............................................23Gas Burner Start Up.....................................................................23Fuel Oil Burner Start Up ...............................................................23

Daily Shut Down....................................................................... 24Change Over (Gas/Fuel Oil)..................................................... 24

From Gas to Fuel Oil ....................................................................24From Fuel Oil to Gas ....................................................................25

Extended Shut Down................................................................ 26

Section 4: Maintenance.................................................. 27Maintenance – General ............................................................ 29Periodic Maintenance Schedule............................................... 29Preventive Maintenance Schedule........................................... 31Troubleshooting........................................................................ 36

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Gas, Fuel Oil or Gas/Fuel Oil Burner – General Operations ........36Gas Operation ..............................................................................37Fuel Oil Operation ........................................................................38

Adjustments ..............................................................................40Gas Pilot Adjustment....................................................................40Gas Pilot Flood Test.....................................................................42Fuel Oil Nozzle Servicing .............................................................43

Section 5: Parts Replacement ........................................45Gas Train Components.............................................................47Firebox Sight Glass ..................................................................47Burner Back Plate Sight Glass .................................................47Expansion Tank Sight Gauge (glass) .......................................48Thermometer (any) ...................................................................48Thermocouple...........................................................................49Heat Transfer Fluid Circulating Pressure Switch ......................49Heat Transfer Fluid Circulating Pressure Gauge......................50Fuel Filter..................................................................................50Fuel Oil Pressure Gauge (any) .................................................50Fuel Oil Solenoid ......................................................................51Fuel Oil Pump...........................................................................52Modulating Fuel Oil Valve.........................................................54Fuel Oil System Bleeding .........................................................57Burner Fuel Oil Ignition Transformer ........................................57Fuel Oil Ignition Gun.................................................................59

Gun Assembly ..............................................................................59Ignition Electrodes........................................................................60Ignition Cables..............................................................................62

Burner Blower Motor.................................................................62Burner Air Flow Switch .............................................................64Burner Gas Ignition Transformer ..............................................66Gas Pilot Assembly...................................................................68

Ignition Electrode..........................................................................69Ignition Cable ...............................................................................70

UV Scanner ..............................................................................71Level Control.............................................................................73Level Control Switch.................................................................74Circulating Motor/Pump Coupling .............................................75Circulating Motor/Pump Coupling Alignment ............................76Circulating Pump Motor ............................................................77Circulating Pump ......................................................................78Electrical Components (Control Box)........................................79Honeywell UDC1200 Modulating Temperature Controller........80

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Configuration ................................................................................80Setup ............................................................................................81

Honeywell UDC120L High Temperature Limit Controller......... 83Configuration ................................................................................83Setup ............................................................................................84

Modulating Motor...................................................................... 85Workbench ...................................................................................87On Heater.....................................................................................89

Air Damper, Gas and/or Fuel Linkage...................................... 91Gas/Air or Fuel/Air Mixture Adjustments .................................. 91

Gas Burner Instructions................................................................92Fuel Oil Burner Instructions..........................................................94

Section 6: Parts.............................................................. 97Overall ...................................................................................... 99Control Box............................................................................. 100

Front Panel .................................................................................100Internal Control Box Components ..............................................101

Drain Pipe Assembly ............................................................. 102Fuel Filter Assembly............................................................... 103Circulating Pump Assembly ................................................... 103Heat Transfer Fluid Plumbing................................................. 104Sight Gauge ........................................................................... 105Burner (blower side) ............................................................... 106Burner (opposite blower) ........................................................ 107Burner - Internal ..................................................................... 108Gas Train................................................................................ 109

1200~1800 Heaters....................................................................1092400~3600 Heaters....................................................................1104900 Heater................................................................................1116300 Heater................................................................................112Modulating Motor........................................................................113

Miscellaneous Parts ............................................................... 114

Section 7: Reference.................................................... 115Heater Specifications ............................................................. 117Alarm Codes........................................................................... 118Safety Lockout Codes ............................................................ 119CONTACT INFORMATION.................................................... 121

CEI Service (General Contact): ..................................................121Department Contact Information ................................................121

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Section 1: Introduction

Introduction

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Jacketed SAFETYFireboxHeaters

SAFETYSafety is of prime concern whenever using an electrically operated, hightemperature device. Please use proper safety precautions and follow all com-pany, local, state and federal regulations for operating potentially dangerousequipment. Lock-out/tag-out equipment before performing maintenance.

IF YOU SMELL GAS

1. Open windows.2. Do not touch electrical switches.3. Extinguish any open flame.4. Call your gas supplier immediately.

Do not store or use gasoline or other flammable liquids and vapors in thevicinity of this or any other appliance.

WARNING!

Improper installation, adjustment, alteration, service or maintenance can causeinjury or property damage. For assistance or additional information consult CEI, aqualified installer, service agency or the gas supplier.

IMPORTANT PRECAUTIONS1. Never attempt to light burner with paper or other materials.2. Never experiment with the burner.3. Never change the fuel or air adjustments without consulting with CEI or a

qualified burner technician.4. Never attempt to light the burner if combustion chamber contains any

unburned fuel or gases.5. Never throw waste paper, rags, garbage, or other waste materials into the

combustion chamber.6. Never wash out heating equipment room without first covering the burner

with waterproof material.

3

Introduction

This manual gives basic instructions which must be observed during installation,operation and maintenance of your CEI Firebox Heater. It is imperative that thismanual be read by the responsible personnel/operator(s) prior to assembly andcommissioning of any heat transfer fluid system. It must always be kept available atthe site of Heater installation. It is not only the general safety instructions con-tained in this Safety section which must be observed, but also the specific informa-tion provided in the following sections and other applicable manuals.

Identification of safety symbols used in this document

Explosion prevention Spray prevention

Fire prevention Lock-Out / Tag-Out

Burn prevention Hot surfaces

Electrocution prevention Environmental protection

Important High pressure

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Jacketed OverviewFireboxHeaters

OverviewThe CEI Jacketed Firebox heater is an efficient, simple method to conduct heat toa heat transfer fluid for use in industries requiring a stable adjustable form of heatsupplied to multiple locations. The standard heater consists of the burner, firebox,skid, heat exchanger, expansion tank, circulating pump and modulating controls.

This manual is intended to be used by owners, operators, and maintenance person-nel to keep your CEI Heater in prime operating condition and to answer commonquestions regarding operating characteristics and capacities.

The heater serial and model numbers are located in two places; 1) an engraved taglocated on the lower right hand corner of the control panel and 2) a stamp on thetop of the skid.

Note: Please supply the serial number when requesting service support or making reference to the heater for spare parts or operational questions.

The heater assembly consists only of the basic heater without options. Variousoptions are available and include:

• Lo-NOx environmental system • High temperature operation (550º F)

• Stack Pack efficiency equipment • Enlarged expansion tank

• 50 cycle power • Removable expansion tank

• 240/380/460 V power options • Bolt-on exhaust stack extensions

• Heavy fuel oil • Heat Transfer Fluid strainers and filters

• Methane fuel • Service contracts

• Manifold and side pump additions • Start-up service

Serial & Model Numbers

5

Introduction

Main ComponentsCEI Jacketed Firebox Heaters for Heat Transfer Fluid (HTF) consist of four pri-mary components:

Burner

The Burner, located at the top end of the Fire Box above the Heat Exchanger, iscapable of burning various fuels, most commonly natural gas, #2 fuel oil or pro-pane.

Jacketed Firebox

The Firebox is the chamber where the fuel is burned. It is surrounded by an fluidfilled jacket where heat is conducted to the Heat Transfer Fluid.

Heat Exchanger

The heat exchanger uses conduction and convection to transfer heat to the HeatTransfer Fluid. The hot gases generated by the burner are directed through boilertubing to the exhaust stack. Turbulators are installed inside the boiler tubing to con-duct heat to the tube inner wall. The turbulators also slightly stir the gases, increas-ing the efficiency of the heat exchanger.

4. Expansion Tank

1. Burner

2. Heat Exchanger

3. Jacketed Firebox

Oil Flow

Yellow = HTF Flow

Red = Heat/Flame Flow

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Jacketed Main ComponentsFireboxHeaters

Expansion Tank

The expansion tank mounted on the top of the CEI Heater is designed as a reser-voir for Heat Transfer Fluid. As the heater is heated the heat transfer fluid expandsand is held at a cooler temperature within the expansion tank. The expansion tankalso serves as a way of purging the heater of trapped air and water.

The expansion tank includes an overflow pipe, fill pipe, level gage, liquid level con-trol, and thermometer. The tank is connected to the top of the firebox where bub-bles of air and water can migrate and be expelled via the overflow/vent.

Other Components

Exhaust Stack

The Exhaust Stack is a vertical tube located at the end of the Heat Exchanger. Insome installations the Exhaust Stack includes a Flue Gas Recovery pipe for Low-NOx applications and/or a Stack-Pack to increase the efficiency of the heater.

Circulating Pump

A Centrifugal Circulating Pump is located before the Supply Pipe Plug Valve.Because the Pump is not a positive displacement type and is located after the Fire-box, the CEI Heater is not considered a pressure vessel and does not requireexpensive certifications.

UV Scanner

The UV scanner is a quartz tube filled with a gas that ionizes when struck by UVradiation from the flame. In the absence of UV radiation, the gas acts as an insula-tor between two electrodes mounted inside the tube. The electrodes are continu-ously energized by a high voltage.

During combustion UV radiation ionizes the gas causing current pulses to flowbetween the electrodes. These current pulses result in a flame signal which is trans-mitted to an amplifier where it is processed to energize or hold in the flame relay.

Fuel Oil Filter (only on Heaters utilizing Fuel Oil)

The CEI supplied fuel oil filter is a step design felt filter with high depth loadingcapacity. Substitute filters should not be used without CEI approval. The CEIHeater is designed with specific requirements for pressure drop, flow rate and fueloil cleanliness. Changing the filter to an unrecognized alternative could adverselyaffect the operation of your Heater.

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Introduction

Control Panel

The Control Panel indicates the current condition of the Heater and is a valuabletroubleshooting tool.

How it OperatesHeat is introduced into the firebox from a positive pressure burner consuming nat-ural gas, fuel oil, propane or other fuels. The flame uses both radiant and directconduction to raise the temperature of the smooth interior of the firebox shelltransferring heat to the surrounding fluid jacket. The high temperature gases aredirected from the burner blast tube toward the back wall of the firebox. These hotgases escape the firebox by flowing back through the heat exchanger where addi-tional heat is transferred to the heat transfer fluid. The spent gases are thenexhausted through the exhaust stack. Several options can be included on theexhaust stack to further improve the efficiency and reduce the emissions of thestandard heater. 85% efficiency is achievable with a standard CEI Heater and anadditional 2-3% efficiency increase is possible with the addition of a Stack Pack tothe exhaust stack.

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Jacketed How it OperatesFireboxHeaters

The Heat Transfer Fluid (HTF) flow is in the opposite direction from that of thehigh temperature gases. The HTF enters the heater from the return pipe into theheat exchanger and then to the fire box jacket. A series of horizontal and verticalbaffles directs the flow of HTF through the heat exchanger optimizing the transferof heat by internal flow turbulence. Blade style turbulators stir the gases and absorbadditional heat flowing through the heat exchanger to optimize heat transfer.

Helical guide rings in the firebox jacket direct the HTF around the full perimeter ofthe firebox. This full contact design provides maximum surface area for heat trans-fer. A centrifugal pump pulls HTF from the firebox jacket discharging it out of theheater supply pipe. A bypass line between the supply and return pipes ensures aconstant flow of HTF through the heater, eliminating any potential for flow disrup-tion from plant piping.

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Introduction

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Section 2: Installation

Installation

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Jacketed InspectionFireboxHeaters

InspectionCEI takes great care in the preparation for and shipping of any CEI Jacketed Fire-box Heater so that it will arrive ready for installation and operation. Howeversometimes the unforeseen happens and damage to the heater occurs during load-ing, shipment and/or delivery.

We recommend a full inspection of the heater for any signs of damage and/ormissing parts before installing the heater.

In the unlikely event that damage has occurred or a part (or parts) is missing, pleasecontact your CEI representative before continuing with the heater installation.

PositionWhen selecting a location for the CEI Jacketed Firebox Heater keep in mind thatthe heater produces significant heat and exhaust. Make certain that the selected siteis level and capable of supporting its fully operational weight. See Heater Specificationson page 117.

Position the heater so that it is supported a minimum of 12" above grade to facili-tate maintenance and cleaning.

Note: Always move the heater with the end opposite the burner section leading the way. Moving the heater any other way may cause damage.

Connect ElectricalVerify that there is sufficient electrical power for the CEI Jacketed Firebox Heaterbefore proceeding. See Heater Specifications on page 117 for the heater’s require-ments.

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Installation

Connect the external electrical power while adhering to any applicable codes.

Note: Power is supplied into the control box and requires a power cable access point (hole) in that box. CEI suggests that the access point be on the bottom of the control box.

Once connected, and before any fuel is supplied to the heater, bump (momentarilyapply power just long enough to verify direction of rotation) both the blower fanand heat transfer fluid circulating pump motors to verify they rotate in the directionindicated on their respective housings.

Note: If the motors DO NOT turn in the indicated direction, turn the power off AT THE SOURCE then swap two of the three power connections at the main breaker. Repeat motor bumping.

When the power is connected and correct motor rotation has been verified, turn allheater switches and the power at the source OFF.

Connect 3 Phase input power to top of Main Breaker.

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Jacketed Connect ElectricalFireboxHeaters

Add Heat Transfer Fluid1. Connect the Heater’s heat transfer fluid supply and return lines to the corre-

sponding external heat transfer fluid lines.Verify that both supply and return line valves on the heater lines areclosed.

2. Open the expansion tank’s sight gauge valves and begin adding Heat TransferFluid (HTF) to the heater through the fill cap on top of the expansion tank.

3. When HTF is just visible in the expansion tank sight gauge apply externalpower. With power ON observe that the Low Level Sensor’s indicator in thecontrol box is illuminated.

Supply Connection

Return Connection

Low Level Sensor LED

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Installation

4. Turn the power back OFF after verifying the sensor’s indicator works.Note: If the Low Level Switch LED indicator does not light, stop adding Heat

Transfer Fluid and correct the problem before proceeding.5. Open the Heat Transfer Fluid bypass valve, both supply and return line valves

and the isolation valve between the firebox and pump.It is important that the bypass valve remains open whenever the heateris operating to help prevent overheating in the case of a clog in theexternal loop.

6. Continue adding HTF until the sight gauge indicates an approximately half-fullexpansion tank. While adding periodically check for leaks and correct asnecessary including any connections not part of the heater.

7. Leaving all control switches OFF, re-apply power to the system.

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8. After verifying that all HTF valves are open, remove the Circulating Pump’svent screw. With the screw removed bump (briefly apply power) the Circu-lating Pump motor. Continue bumping the Circulating Pump motor until HTFis coming out of the vent screw hole without any air bubbles. Replace the ventscrew.

9. Turn on the Circulating Pump motor while leaving the Burner switch OFF.10. Use the bleed valve on the pipe exiting the circulating pump to bleed air out of

the heater (most air in the system is bled out in the expansion tank).

Vent Screw

MotorConnection

Hot Oil IN

Hot Oil OUT

Bleed Valve

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Installation

11. Watch the heat transfer fluid level in the expansion tank as air is bled from thesystem. Add heat transfer fluid as necessary to keep the tank level approxi-mately ¼ full. Stop adding heat transfer fluid when all air has been bled fromthe system.

12. Turn all heater switches and the power at the source OFF. Replace the fill capon the expansion tank.

Natural Gas / PropaneNote: If the CEI Jacketed Firebox Heater is Fuel Oil only, skip to Fuel Oil on page 19.

1. Verify that there is a sufficient supply of Natural Gas (or Propane) for the CEIJacketed Firebox Heater before proceeding. See Heater Specifications onpage 117 for the heater’s requirements.

2. Make sure the heater’s gas inlet supply valve is closed then connect the Gassupply to the inlet on the Heater. Open the source gas supply valve and checkfor leaks. Correct as necessary.

3. If the heater is a combination Gas/Fuel Oil heater AND fuel oil is not beingused at this time, remove and store the coupling between the blower motorand the fuel oil pump.To remove the coupling:a. Remove all six flange nuts w/washers holding the blower motor/fan

assembly to the burner and take the assembly far enough out of the hous-ing to access the rubber coupling.

Gas Inlet Valve(shown closed)

Gas Supply Inlet

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CAUTION! - The blower motor/fan assembly is heavy. Use care in handling it.Note: When removing the assembly be careful not to damage the rubber coupling between

the fan and the fuel oil pump.

b. Remove the coupling and store it for later use.c. Reinstall the blower motor/fan assembly.

4. When the motor/pump coupling has been removed go to Initial Startup onpage 20. If fuel oil is to be connected at this time continue below.

Fuel OilNote: If the CEI Jacketed Firebox Heater is Gas only, or a combo heater that is not being

set up for fuel oil at this time, skip to Initial Startup on page 20.

1. Make sure the valve on the fuel oil supply is closed then connect the fuel oilsupply line using a flared connection to the fuel oil inlet on the heater.

Flange Nuts

Blower Motor

Fuel Oil Inlet

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Installation

2. Once connected, open the valve on the fuel oil supply and check for leaks.Correct as necessary.

3. If the heater is a combo unit that has been operating on gas and the motor/pump coupling was removed for the gas operation, reinstall the coupling andcoupling cover.Reverse step 3 under Natural Gas / Propane above to install the coupling.

Initial StartupCAUTION! - Raise the heat transfer fluid temperature slowly. Rap-idly raising the heat transfer fluid temperature will cause an overflowand potential fire.

1. Turn the Heater Switch ON then set the UDC1200 Modulating TemperatureController to 200°F.

2. Once the temperature stabilizes at 200°F let it remain at that temperature for 2hours.

3. Set the UDC1200 Modulating Temperature Controller to 220°F.4. Once the temperature stabilizes at 220°F let it remain at that temperature for 2

hours.5. Repeat steps 3 and 4 increasing the temperature in 20°F increments until the

desired temperature is reached (normally 300°F).6. Recheck for leaks and heat transfer fluid level. Turn the power off and let the

heater and heat transfer fluid cool before correcting leaks and/or addingadditional heat transfer fluid.

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Section 3: Operation

Operation

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Jacketed Daily Start UpFireboxHeaters

Daily Start UpNote: Daily Start Up is only necessary when the heater was shut down for a short period

(i.e. overnight or maintenance)

Preparation for Start Up - All Fuels1. Ensure that the heater is in working order.

Note: Fuel Oil burner – Make sure that the fuel oil tank has an adequate fuel level and that the fuel is the proper grade.

2. Set the burner control panel switch to the OFF position.Note: Combination Gas/Fuel Oil burner – Set the fuel selector switch to the fuel to be

burned.3. Turn the thermostat or operating control down to its lowest setting.4. Check fuses and replace as necessary.5. Depress the flame safeguard programming control reset button.

Gas Burner Start Up1. Manually open and close the main gas shut off cock, leak test cock and pilot

cock to determine that they operate freely. Open all three cocks. (Reset low gaspressure switch if supplied.)

2. Set the main power switch and burner panel control switch to the ONposition. Wait 30 seconds and turn up thermostat or operating control to thedesired setting.

3. The burner blower motor will start and after a suitable pre-purge period (thiswill vary with the type of flame safeguard control supplied - but will usually bea minimum of 30 seconds to a maximum of 90 seconds) the burner pilot willlight, after which the main flame will be established.

If the heater does not respond properly contact CEI or a qualifiedburner service company.

Note: For combination Gas/Fuel Oil heaters open all fuel oil line valves (fuel oil must circulate through the fuel oil pump, even when burning gas).

Fuel Oil Burner Start Up1. Open all valves in fuel oil lines.2. Set the main power switch and burner panel control switch to the ON

position. Wait 30 seconds and turn up thermostat or operating control to thedesired setting.

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Operation

3. The burner blower motor will start. Depending upon the type of flamesafeguard control supplied, the fuel ignition system may energize within 1 or 2seconds after the blower motor starts or could be as long as 90 seconds.

If the heater does not respond properly contact CEI or a qualifiedburner service company.

Daily Shut DownNote: Daily Shut Down is only necessary if the heater will be shut down for a short period

(i.e. overnight or for routine maintenance)

1. Turn the Burner control panel switch OFF. However, be sure to leave theCirculating Pump switch ON for at least 10 additional minutes to allow theheat transfer fluid to evenly cool.

2. Close all valves in gas and fuel oil lines.

Change Over (Gas/Fuel Oil)Note: Change Over is for those dual energy burner installations where the heater normally

runs on one energy source and is switching to an alternate energy source.

From Gas to Fuel Oil1. Turn the heater’s main circuit breaker OFF.2. Close both the heater’s gas inlet valve and the source gas valve.3. Disconnect the gas line from the heater at the gas inlet connection.

Note: If the heater will only be operating on fuel oil for a short period the gas line may be left connected. However, be sure to close both the inlet and source gas valves.

4. If necessary install the coupling between the blower motor and fuel oil pump(installations that primarily run on gas usually have the coupling between theblower motor and fuel oil pump removed).To install the coupling:a. Remove all six flange nuts w/washers holding the blower motor/fan

assembly to the burner and take the assembly far enough out of the hous-ing to access the rubber coupling location.

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Jacketed Change Over (Gas/Fuel Oil)FireboxHeaters

CAUTION! - The blower motor/fan assembly is heavy. Use care in removing it.

b. Install the coupling into the flange on the fuel oil pump.c. Reinstall the blower motor/fan assembly making sure the flange on the

end of the shaft properly lines up with the coupling.5. Connect the source fuel line to the fuel inlet on the heater.6. Change the GAS /OIL switch on the Control Box to OIL.7. Open the source fuel valve and check for leaks. Correct as necessary.8. Go to Fuel Oil Burner Start Up on page 23.

From Fuel Oil to Gas1. Turn the heater’s main circuit breaker OFF.2. Close the source fuel valve and all fuel valves on the heater.3. Disconnect the source fuel line from the fuel inlet on the heater.4. Remove the coupling between the blower motor and fuel oil pump if the

switch from fuel to gas is anticipated to be long term. See step 3 under NaturalGas / Propane in Installation for directions.

Note: When the switch from fuel to gas is expected to be short term it’s acceptable to leave the coupling in place as long as you ensure that the pump has a good fuel oil supply so that it will not run dry when the burner is operating on the gas cycle.

Be certain that the pump is adequately primed to prevent against mechanical seizure caused by lack of fuel oil.

5. Connect the source gas line to the gas inlet on the heater.

Flange Nuts

Blower Motor

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Operation

6. Change the GAS /OIL switch on the Control Box to GAS.7. Open the source gas valve and check for leaks. Correct as necessary.8. Go to Gas Burner Start Up on page 23.

Extended Shut Down1. Place main power switch and burner control panel switch to the OFF position.2. Close all valves in gas and fuel oil lines.3. Cover burner to protect it from dust and dampness.

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Section 4: Maintenance

Maintenance

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Jacketed Maintenance – GeneralFireboxHeaters

Maintenance – GeneralOnly qualified service technicians should make mechanical or electrical adjustmentsto the burner and/or associated control equipment.

Maintenance personnel can perform preventive most maintenance procedures.

Observe and follow the safety information covered in SAFETY on page 3 andDaily Start Up on page 23 (when appropriate).

Turn the burner power supply OFF and close manual fuel valves as appropriate forroutine maintenance.

Make sure that combustion and ventilation fresh air sources to the burner roomremain clean and open.

Periodically check all electrical connections and make sure the flame safeguard con-trol chassis is firmly connected to its wiring base.

Refer to manufacturer’s product bulletins supplied with the burner for maintenanceon the flame safeguard control and other components.

Periodic Maintenance ScheduleItem Frequency Checked By Remarks

Gages, monitors and indicators

Daily Operator Make visual inspection and record readings in log

Instrument and equipment Daily Operator Make visual checks of the heater settings compared to CEI’s recommended specifications

Firing rate control Weekly

Semiannually

Annually

Operator

Service Technician

Service Technician

Verify heater meets CEI’s recommended settings

Verify heater meets CEI’s recommended settings

Check with combustion test

Flue, vent, stack, or outlet damper

Monthly Operator Make visual inspection of linkage, check for proper operation

Combustion air Monthly Operator All sources remain clean and open

Ignition System Weekly Operator Make visual inspectionCheck the Fireye flame signal strength readout, should be greater than 25(see Combustion safety controls below)

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Maintenance

Fuel Valves

Pilot and main Weekly Operator Open limit switch-make aural and visual check. Check valve position indicators and check fuel meters if so fitted

Pilot and main gas or main fuel oil

Annually Service Technician Perform leakage tests-refer to valve manufacturer’s instructions

Combustion safety controls

Flame failure Weekly Operator Close manual fuel supply for (1) pilot, (2) main fuel cock, and/or valve(s): check safety shutdown timing; log

Flame signal strength Weekly Operator If flame signal meter installed, read and log; for both pilot and main flames, notify service organization if readings are very high, very low, or fluctuating; refer to flame safeguard manufacturer’s instructions

Pilot turndown test As required annually

Service Technician Required after any adjustments to flame scanner mount or pilot burner; verify annually-refer to flame safeguard manufacturer’s instructions. See Gas Pilot Adjustment on page 44.

Refractory hold in As required annually

Service Technician See Gas Pilot Adjustment on page 44.

High limit safety control Annually Service Technician Refer to burner manufacturer’s instructions

Operating control Annually Service Technician Refer to burner manufacturer’s instructions

Low draft, fan, air pressure and damper

Monthly Operator Refer to this manual and control manufacturer’s instructions

High and low gas pressure interlocks

Monthly Operator Refer to instructions in this manual

Low fuel oil pressure interlocks

Monthly Operator Refer to instructions in this manual

Fuel valve interlock switch Annually Service Technician Refer to valve manufacturer’s instructions

Purge switch Annually Service Technician Refer to fuel/air control motor manufacturer’s instructions

Low fire start interlock Annually Service Technician Refer to fuel/air control motor manufacturer’s instructions

Automatic changeover control (dual fuel)

At least annually

Service Technician Under supervision of gas utility

Inspect burner components At least annually

Service Technician Refer to this manual and control component manufacturer’s instructions

Remove fuel oil drawer assembly

Annually Service Technician Remove and clean

Check blower motor and blower

Annually Service Technician Remove and clean wheel for cleanliness.Remove and clean as necessary

Remove, inspect and clean gas pilot assembly

Annually Service Technician Remove and clean

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Jacketed Preventive Maintenance ScheduleFireboxHeaters

Preventive Maintenance Schedule

Maintenance

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Record base point numbers

X Having base point numbers will help troubleshooting if problem occur

Prime Circulating Oil Pump seal area

X CRITICAL – May cause pump damage if not done at start-up

Check motors rotation X Fan has indicating labelCirculating pump has indicating arrow cast into its frame.

Check fuel pressure gauges

X Gas Inlet & Manifold Pressure GaugesFuel Oil Main & Bypass Pressure Gauges

Gas Inlet Gauge

Gas Inlet Connection

Main Fuel Oil Pressure Gauge

Bypass Fuel Oil Pressure Gauge

Manifold Gas Pressure Gauge

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Maintenance

Check for clear exhaust X X Adjust burner fuel pressure and damper openings as required

Check for leaks X X

Visually check the burner for debris and/or blockage at blower

X X

Visual check of Heat Transfer Fluid pressure

X X Log pressure readings

Set temperature limits and alarms

X X See Heater Console on page 13.

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Check Exhaust

Heat Transfer Fluid Pressure Gauge

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Grease Plug Valves X X

Use p/n 1501131 (Plug Valve Grease cartridge)

Heat Transfer Fluid level X X X Check level daily, analyze fluid annually

Heat Transfer Fluid filter/strainer

X If present (optional, supplied by customer), check filter or strainer daily during first full week of operation and after heater maintenance; monthly thereafter.Replace or clean as required.

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Grease fitting on Plug Valve(under dust cap in photo)

Fluid Level Indicator

Fluid Temperature(in expansion tank)

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Maintenance

Grease circulating pump X The circulating pump bearings consist of one outboard grease lubricated ball bearing and one internal liquid flushed carbon sleeve bearing. The ball bearing should be lubricated at the following intervals:

Use the following quantities of grease:

Use a lithium-soap grease lubricant free from resins and acids, protects against rust, and is suitable for high temperature.

Fuel oil filter(s) X Depends on quality of fuel oil

Clean components external

X X Environmental conditions will dictate schedule

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Pump speed Lubrication interval

1450 rpm 3200 hours of operation




Bearing bracket Grease (g)

25 9

35 15

Fuel Oil Filter

Fuel Oil Inlet Connection

34


Remove to examine and clean UV Scanner

X Check for soot build-up – clean as needed

Check Flame Safeguard System

Check flame signal strength for degradation.Close main and pilot fuel valves to verify shut-down sequence and timing.Log all events and timing.

Clean burner blower X Remove blower motor and clean blower wheel and blower housing.

Maintenance

Star

t-up

Dai

ly (v

isua

l che

ck)

Wee

kly

Mon

thly

Year

ly

Notes

UV Scanner

35

Maintenance

Troubleshooting

Gas, Fuel Oil or Gas/Fuel Oil Burner – General Operations

Burner Fails to Start1. Defective ON/OFF or Fuel Transfer switch. Replace.2. Control circuit has an open control contact. Check limits, low heat transfer

fluid cutoff, proof of closure switch and others as applicable.3. Bad fuse or switch open on in-coming power source. Correct as required.4. Motor overloads tripped. Reset and correct cause for overload trip.5. Flame safeguard control safety switch tripped. Reset and determine cause for

apparent flame failure.6. Loose connections. Tighten all terminal screws.7. Frozen fuel oil pump shaft preventing blower motor operation. Replace fuel

oil pump.8. Flame safeguard control starting circuit blocked due to flame relay being

energized (display shows False Flame):• Possible defective scanner – replace.• Possible defective amplifier – replace.• Scanner actually sighting flame due to leaking fuel valve – correct unwanted

flame cause.• Defective flame safeguard control – replace.• External light source reaching sensor through firebox sight glass - correct.

9. Defective blower motor. Repair or replace.

Occasional Lockouts for No Apparent Reason1. Gas pilot ignition failure. Readjust to make certain that ignition is instant and

that flame signal readings are stable and above minimum values. Make certainthe pressure is correct at the pilot test tee.

2. Gas pilot ignition and direct spark fuel oil ignition. Verify that there are nocracks in the porcelain. Check that both transformer and electrode end plugsconnections are tight.

3. Loose or broken wires. Check all wire nut connections and tighten all terminalscrew connections in panel and elsewhere as appropriate.

4. Occasional low voltage supply. Have local utility correct.5. Occasional low gas supply pressure. Have local utility correct.6. Air leak in fuel oil suction line or check valve not holding. Correct as required.

36

Jacketed TroubleshootingFireboxHeaters

Gas Operation

Burner Motor Runs but Pilot Does Not Light1. Gas supply to burner shut off – make sure all manual gas supply valves are

open. Automatic high pressure valve at meter such as Sentry type tripped shutdue to high gas pressure – reset valve and correct cause for valve tripping.

2. Pilot solenoid valve not opening – listen and feel for valve actuation. Solenoidvalve not being powered – check electrical circuitry. Replace coil or entire valveif coil is burned out.

3. Defective gas pilot regulator. Replace.4. Gas pressure too high or too low at pilot orifice. Readjust gas pilot as required.5. Defective ignition transformer – replace.6. Defective Fireye YB-110UV Safety Control or YP-138 Programmer. Replace

as required.7. Air flow switch not making circuit – check out electrically and correct pressure

adjustment on switch if required. Defective air flow switch. Replace. Airswitch negative pressure sensing tube out of position – reposition as necessary.

Burner Motor Runs & Pilot Lights but Main Gas Flame is NOT Established1. Main shut off or test cock closed. Check to make certain fully open.2. Pilot flame signal reading too low to pull in flame safeguard relay. Readjust gas

pilot as required.3. Defective automatic main or auxiliary gas shut off valves. Replace valve(s) as

required.4. Defective flame safeguard control or plug in amplifier. Check and replace as

required.5. Butterfly valve incorrect. Readjust as required.6. Main gas pressure regulator atmospheric vent line obstructed. Correct.7. Defective main gas pressure regulator. Replace.

Carbon Monoxide Readings on Gas Firing1. Flame impingement on cold heat transfer surfaces caused by excessive firing

rate. Reduce firing rate to correct input volume.2. Incorrect gas/air ratios. Readjust burner to correct CO2/O2 levels to reduce

CO formation to appropriate level.

Gas High Fire Input Cannot Be Achieved1. Gas company pressure regulator or meter operating incorrectly not allowing

required gas pressure at burner train inlet. Have gas company correct.2. Gas cock upstream of train inlet not fully open. Check and correct.

37

Maintenance

3. Gas line obstructed. Check and correct.4. Gas train main and/or leak test cocks not fully open. Check and correct.5. Automatic gas valve not opening fully due to defective operation. Replace.6. Butterfly valve not opening to proper operating position. Readjust.7. Defective main gas pressure regulator. Replace.8. Main gas pressure regulator vent line obstructed. Check and correct.9. Normally open vent valve (if supplied) not closing when automatic gas valves

open. Check to see if valve is fully closed when automatic valves are open.Replace vent valve if not closing fully.

Fuel Oil Operation

Burner Motor Runs but Direct Spark Ignited Fuel Oil Flame is NOT Established1. Defective fuel oil nozzle. Remove and clean or replace.2. Low fuel oil pressure. Check with gauge for correct light-off pressure.3. Defective fuel oil pump. Replace.4. Defective fuel oil solenoid valve. Replace.5. Fuel oil pump coupling loose or defective. Replace or tighten as required.6. Low fuel oil pressure switch (if supplied) defective or incorrectly set. Adjust or

replace switch.7. Ignition transformer defective. Replace.8. Ignition electrodes cracked and grounding out spark. Replace electrodes.9. Ignition lead wire defective and grounding spark out. Replace.10. Ignition plug in connections at transformer or electrodes loose. Tighten.11. Air flow switch not making. Reset pressure or replace.12. Defective flame safeguard control or plug in purge timer card. Replace.13. Air dampers held in high fire position due to mechanical binding of linkage.

Readjust linkage.14. Loose wiring connections. Check and tighten all connections.

Fuel Oil Flame Ignites but then Flame Safeguard Control Locks Out on Safety1. Flame scanner lens dirty. Remove and clean.2. Scanner sight tube blocked or dirty. Check and clean.3. Flame scanner defective. Replace.4. Defective fuel oil nozzle causing unstable flame and scanning problems.

Replace fuel oil nozzle.5. Fuel/air ratios incorrect resulting in unstable or smoky flame causing scanner

38

Jacketed TroubleshootingFireboxHeaters

flame sighting problem. Readjust ratios for clean stable flame.6. Defective flame safeguard amplifier or control. Replace as appropriate.

Fuel Oil Flame Extremely Smoky at Light Off or in Low Fire Position1. Defective fuel oil nozzle. Replace.2. Fuel/air ratio incorrect. Readjust.3. Normally closed fuel oil solenoid valve in fuel oil nozzle return line not

opening. Check electrical circuitry and replace valve if defective.4. Normally open pump mounted solenoid valve malfunctioning. Replace valve

or pump.

Light Off Fuel Oil Flame Is Established and Proven but Burner Will Not Attempt to Go to the High Fire Position

1. Burner high fire temperature or pressure control could be defective or not setto call for high fire. Readjust or replace control.

2. Loose wires. Verify wiring and tighten all connections.3. Flame safeguard control or high fire panel switching relay (if supplied)

defective. Verify and correct as required.4. High fire 3 way solenoid valve defective. Replace.5. Hydraulic fuel oil cylinder defective. Replace.6. Linkage mechanically binding. Readjust linkage.7. Defective modulating motor. Replace.

Low Fuel Oil Flame Is Established and Proven but Flame Out Occurs in Tran-sition from Low Fire to High Fire

1. Defective fuel oil nozzle. Replace.2. High fire fuel oil pressure too low. Readjust.3. Air dampers set too far open at low fire causing flame to blow out in starting

to high fire. Readjust dampers.4. Fuel oil pump coupling loose or defective. Tighten or replace.5. Defective fuel oil pump. Replace.6. Linkage mechanically binding. Readjust.7. Fuel/air ratios incorrect causing flame to blow out when going to high fire.

Readjust linkage.

White Smoke Formation on Fuel Oil FiringFuel Oil/Air ratios incorrect due to excess air or fuel oil flow is too low. Read-just for proper fuel input, CO2 and smoke reading.

39

Maintenance

Gray or Black Smoke Formation on Fuel Oil Firing1. Impingement on cold combustion chamber surfaces due to incorrect fuel oil

nozzle spray angle for application. This could also result in carbon formationon chamber surfaces. Change nozzle spray angle in order to shorten or narrowthe flame as required.

2. Defective or dirty fuel oil nozzle. Replace or clean nozzle.3. Incorrect fuel oil/air ratios. Readjust burner to correct CO2 and smoke levels.4. Fuel oil pressure too low resulting in poor atomization. Readjust.

Fuel Oil High Fire Input Rate Cannot Be Achieved1. Nozzle defective. Replace. Nozzle mesh filter dirty – clean or replace.2. Fuel oil supply pressure to nozzle too low. Readjust.3. Fuel oil pump defective. Replace.4. Fuel oil pump coupling loose (slipping) or defective. Replace.5. Linkage mechanically binding. Readjust.6. Fuel oil nozzle return line metering valve setting incorrect. Readjust to attain

required nozzle bypass pressure.7. Blocked or dirty suction line fuel oil filter. Replace or clean.8. Manual valves in suction line not fully open. Check and correct.9. Suction line check valve operating incorrectly. Check and correct.10. Vent system on fuel oil tank blocked creating vacuum on tank, with high

vacuum and lowered fuel oil flow to burner. Check and correct.

Adjustments

Gas Pilot Adjustment

Excessive gas pressure and insufficient air are the most common causes of pilotignition failure. Nominal pilot gas pressures are as follows:

Note: Do not increase pressure beyond that required for a stable flame signal.

Model Number Nominal Pilot Pressure

CEI-1200 2" - 4" W.C.

CEI-1800 / 2400 1½" - 3" W.C.

CEI-3600 / 4900 / 6300 1½" - 2" W.C.

40

Jacketed AdjustmentsFireboxHeaters

Read the gas pressure at the test tee on the pilot gas supply pipe with a manometeror 0 to 10" W.C. gauge. Look for stability of gas pressure at all times. For depend-able pilot ignition, always use air damper setting to provide MOST air and LOW-EST pilot gas pressure setting allowable for good pilot signal at all times.

Note: There is a tendency to set the air dampers in a closed, barely open position. This action may produce insufficient air for dependable pilot ignition. Air damper openings should be at least ¼" on each damper (or ½" on one, with the other nearly closed). Some job conditions may require larger air damper openings than those shown above.

1. Remove the pilot assembly and check for proper spark gap. The spark gapbetween the electrode and the outside radius of the gas pilot assembly shouldbe 1/16" - 3/32". DO NOT set the spark to arc against the pilot head nozzle.

2. Close the checking cock (test cock). Start up burner and stop flame safeguardcontrol timer with check switch during pilot ignition.

3. Observe the pilot signal with a DC voltmeter or microammeter. Reduce thepilot gas pressure to a point where the signal is erratic or reduced substantiallyfrom the initial reading.

4. Raise the pilot gas pressure to a point where the pilot signal is again stable.Remove the scanner and use a mirror to view the pilot flame through thescanner pipe. Be sure to get full coverage of scanner pipe by pilot flame.

Note: A live flame from cigarette lighter or butane torch may be needed to keep scanner actuated while viewing the pilot flame.

1/16" - 3/32"Spark Gap - Electrode Tip to Pilot Case

2 15/16"Air Hole

Primary Air Holes (2)

Pilot Orifice

CEI-1200 / 1800 / 2400 Electrode Adjustment


Air Hole


Pilot Orifice

3 1/16"


41

Maintenance

Release the check switch and observe the meter as the main gas valve opensand moves the air damper. If there is a drop in signal as this happens, increasepilot pressure slightly until signal is steady at all times.

5. Perform the Gas Pilot Flood Test below.

Gas Pilot Flood Test

Many pilot problems are caused by a poor mixture of gas and air at the point ofignition (ignition spark gap). The cause of this poor mixture condition is usuallyexcessive gas flow or insufficient air (air dampers are closed too far).1. Turn the burner off and shut the manual leak test cock in the main gas train.

Note: The manual leak test cock valve should always be closed when making pilot adjustments.

2. Take steps to keep the fuel air linkage in the pilot light off position. Place theflame safeguard timer check switch in the test position.

3. Install a manometer or 0 to 10" W.C. gas pressure gauge in the pilot test teefitting. Plug an appropriate flame signal meter into the flame safeguardcontrol.

CAUTION! the ignition transformer generates 6000 volts.4. Disconnect the high tension ignition lead wire at the ignition transformer

secondary terminal. Either hold onto the insulated portion or let the freeignition wire hang loose making sure it cannot come into contact with the bareignition terminal on the transformer.

5. Start the burner and let it go through the prepurge period. When the pilotignition circuit energizes (listen for the sound of the solenoid valve opening orwatch the pilot gas pressure gauge) wait about 3 to 4 seconds thenCAREFULLY touch the ignition lead wire to the transformer terminalsecondary.If the pilot fuel/air mixture and ignition electrode are adjusted correctly, thepilot will light instantly and the flame signal reading will be steady and of thecorrect value. Continue to step 6.If the pilot does not light instantly readjust the pilot gas pressure and/or the air dampers and/or the ignition electrode setting.

6. Turn the burner off. Reconnect the ignition lead wire to the ignition trans-former secondary terminal. Set the check switch in the flame safeguardcontrol for automatic operation. Open the checking gas cock, turn the burneron and verify that the pilot lights and proves instantly providing good, smoothignition of the main gas flame.

A successful Gas Pilot Flood Test does not always a guarantee correct pilotair/fuel mixture. However, a failure almost always indicate an excessivelyrich mixture.

42

Jacketed AdjustmentsFireboxHeaters

Fuel Oil Nozzle ServicingNote: When removing or replacing the fuel oil nozzle and electrode assembly, take care to

prevent damage to the ignition wire.1. Remove the entire Fuel Oil Ignitor Gun Assembly for ease of service.2. Disassemble (do not force disassembly) and thoroughly clean the nozzle with

a liquid solvent (preferably non-flammable) and a brush. If the nozzle isdamaged or burned, replace it.

3. Check the strainer. Clean or replace as necessary.

Note: Do not use a screwdriver, wire brush or similar metallic objects to clean nozzles. Damage to orifices or spray slots result in off-center or sparky fires.

4. Remove and clean the ignitor assembly including the porcelain insulators.Replaced the porcelain insulators if cracked.

5. Check the electrode tips and diffuser as indicated below and adjust asnecessary:

5/16” from the tip of the Nozzle to the ark point5/16” from the center of the Nozzle out (up in photo) to the Electrodes

Nozzle Tip

Distributor

Strainer

Combination Locknut& Strainer Support

Adapter

Seal Bushing

43

Maintenance

6. Check that the diffuser is uniformly flat with approximately 1/4" to 5/16"between the blades.

7. Check the high tension wires and clips between the transformer and ignitorelectrodes for deterioration.

8. Re-seat the nozzle firmly in the nozzle adapter to prevent leaks.

5/16” from the tip of the Nozzle to the back of the Diffuser

1/16” gap between Electrodes

44


Section 5: Parts Replacement

Parts Replacement

46

Jacketed Gas Train ComponentsFireboxHeaters

Gas Train ComponentsBecause components in the Gas Train should only be replacedand/or adjusted by qualified personnel CEI has not includedreplacement instructions for these components in this manual.

Firebox Sight GlassLet the Heater cool before removing or replacing the Sight Glass.

1. Unscrew the cap holding the Sight Glass and remove it from the firebox.2. Remove the three screws holding the sight glass in the cap and remove the

sight glass.

3. Reverse the procedure to install the replacement sight glass.

Burner Back Plate Sight GlassLet the Heater cool before removing or replacing the Sight Glass.

1. Remove the two screws holding the burner back plate in place then slide theplate down and off.

2. From the inside of the plate pop the sight glass ring out of the plate.3. Reverse the procedure to install the replacement sight glass.

Sight Glass mount screws

47

Parts Replacement

Expansion Tank Sight Gauge (glass)Let the Heater and Heat Transfer Fluid cool before removing or replacingthe Expansion Tank Sight Gauge.

1. Close both expansion tank sight gauge valves.2. Loosen the two compression fittings on either end of the sight gauge - remove

the gauge.3. Using new rubber gaskets, install the new sight gauge and tighten the

compression fittings.4. Open both expansion tank sight gauge valves and check for leaks - correct as

necessary.

Thermometer (any)Let the Heater and Heat Transfer Fluid cool before removing or replacing aThermometer.

CAUTION! - Make sure to unscrew the thermometer and NOT the thermowell.

1. Unscrew the thermometer from the thermowell and remove the thermometer.2. Screw the new thermometer into the thermowell using gas/oil resistant pipe

thread compound on the threads. Pay attention to the readability of thethermometer.

Thermometer nut

Thermowell nut

48

Jacketed ThermocoupleFireboxHeaters

ThermocoupleCAUTION! - Make sure power is disconnected and locked outbefore removing or replacing the Thermocouple.

Let the Heater cool before removing or replacing the Thermocouple.

1. Remove the cover over the electrical connections, label the wiring (white ispositive, red is negative) then disconnect the wiring. Disconnect the electricalconduit from the thermocouple and move it and its cable out of the way.

2. Unscrew the thermocouple assembly from the firebox and remove the unit.3. Reverse the procedure to install the replacement thermocouple using gas/oil

resistant pipe thread compound on the threads.4. Remove the lockout and restore power.

Heat Transfer Fluid Circulating Pressure SwitchCAUTION! - Make sure power is disconnected and locked outbefore removing or replacing the Heat Transfer Fluid Circulat-ing Pressure Switch.

Let the Heater cool before removing or replacing the Heat Transfer FluidCirculating Pressure Switch.

1. Close the Heat Transfer Fluid Isolation, Supply and By-pass valves.2. Place a drip pan under the switch location - a significant amount of Heat

Transfer Fluid may leak out of the pipe where the switch is installed.3. Remove the cover over the electrical connections, label the wiring then

disconnect the wiring. Disconnect the electrical conduit from the switch andmove it and its cable out of the way.

4. Unscrew and remove the switch.5. Reverse the procedure to install the replacement switch using gas/oil resistant

pipe thread compound on the threads.6. Remove the lockout and restore power.

49

Parts Replacement

Heat Transfer Fluid Circulating Pressure GaugeLet the Heater cool before removing or replacing the Heat Transfer FluidCirculating Pressure Gauge.

1. Close the Heat Transfer Fluid Isolation, Supply and By-pass valves.2. Place a drip pan under the gauge location - a significant amount of Heat

Transfer Fluid may leak out of the pipe where the gauge is installed.3. Unscrew and remove the gauge.4. Reverse the procedure to install the replacement gauge using gas/oil resistant

pipe thread compound on the threads.Note: Wait at least 10 minutes for the pipe thread compound to set before continuing.

Fuel FilterLet the Heater and cool before removing or replacing the Fuel Filter.

Note: Fuel oil between the filter and the first fuel solenoid, and fuel oil between the filter and fuel oil supply valve, will leak out when the filter housing is removed.

1. Place a drip pan under the fuel filter to catch leaking fuel oil.2. Close the fuel oil supply valve (at the fuel oil supply).3. Unscrew the filter housing and remove the old filter.4. Place the new filter into the filter housing and inspect the filter housing O-ring

making sure it is seated properly. Replace the O-ring if necessary.5. Screw the filter housing back into place then remove the drip pan.6. Open the fuel oil supply valve and check for leaks. Correct as necessary. If

necessary go to Fuel Oil System Bleeding on page 57.

Fuel Oil Pressure Gauge (any)Let the Heater cool before removing or replacing a Fuel Oil Pressure Gauge.

1. Place a drip pan (or drip rag) under the defective pressure gauge then removethe gauge.

50

Jacketed Fuel Oil SolenoidFireboxHeaters

2. Put gas/oil resistant pipe thread compound on the threads of the replacementgauge then install the gauge. Remove the drip pan.

Note: Wait at least 10 minutes for the pipe thread compound to set before continuing.3. Start the heater on fuel oil to confirm proper operation. If fuel oil pressure is

incorrect go to Fuel Oil System Bleeding on page 57.

Fuel Oil SolenoidCAUTION! - Make sure power is disconnected and locked outbefore removing or replacing the Fuel Oil Solenoid.

Let the Heater cool before removing or replacing a Fuel Oil Solenoid.

1. Place a drip pan (or drip rag) under the defective solenoid then disconnect thefuel oil line flare connections.

Upper solenoid fuel oil line flare connections

Lower solenoid fuel oil line flare connections

51

Parts Replacement

2. Open the PowerFlame terminal box and locate where the leads from bothsolenoids are connected together.

3. Remove the cable ties then disconnect the solenoid wires from one another.4. Remove the conduit nut holding the defective solenoid in place and remove

the solenoid.5. Install the replacement solenoid using the nut from above.6. Connect the solenoid wires together and add cable ties.7. Reconnect the fuel oil lines and remove the drip pan.8. Remove the lockout and restore power.9. Start the heater on fuel oil to confirm proper operation. If fuel oil pressure is

incorrect go to Fuel Oil System Bleeding on page 57.

Fuel Oil PumpCAUTION! - Make sure power is disconnected and locked outbefore removing or replacing the Fuel Oil Pump.

Let the Heater cool before removing or replacing the Fuel Oil Pump.

1. Close the fuel oil supply valve (at the fuel oil supply).

Leads from both solenoids are connected together here.

52

Jacketed Fuel Oil PumpFireboxHeaters

2. Place a drip pan (or drip rag) under the fuel oil pump then disconnect the flareconnections for the fuel oil supply and return lines, the coupling for the fueloil solenoids, and the coupling for the fuel oil check valve (indicated below).

3. Remove the two bolts holding the fuel oil pump then remove the pump andthe attached plumbing.

Note: When removing the assembly be careful not to damage the rubber coupling between the fuel oil pump and fan.

4. Mark the position of the coupling’s flange on the motor shaft then loosen itsset screws and remove the flange. Measure the distance from the motor shaftend to the mark just made.

5. Remove the fuel oil supply pipe, T fitting and coupling fitting from the pump.6. Install the blower/fuel oil pump coupling flange on the replacement pump’s

shaft at the distance measured in step 4.7. Put gas/oil resistant pipe thread compound on the threads of the items just

removed then install then on the replacement pump making sure to align theparts as they were on the old pump.

Note: Wait at least 10 minutes for the pipe thread compound to set before continuing.8. Install the new pump reversing the steps above.

Note: Be sure to properly align the fuel oil pump with the rubber coupling and the fan shaft.9. Align the damper to the linkage where it was marked in step 4 and tighten the

linkage.10. Reconnect the fuel lines disconnected in step 2.11. Remove the drip pan and open the fuel oil supply valve.12. Remove the lockout and restore power.

Flare Connection(to fuel oil check valve)

Flare Connection(to fuel oil solenoids)

Fuel Oil Pump

Fuel Oil Flare ConnectionsSupply (right) and Return (left)

Shown NOT connected in photo

53

Parts Replacement

13. Start the heater on fuel oil to confirm proper operation. If fuel oil pressure isincorrect go to Fuel Oil System Bleeding on page 57.

Modulating Fuel Oil Valve1. Shut the fuel oil supply OFF then start the heater and let it run through pre-

purge.• As the modulation motor repositions the modulating fuel oil valve’s pointer

to low fire, record the position of the pointer.

• As the modulation motor repositions the modulating fuel oil valve’s pointerto high fire, record the position of the pointer.

Note: The pointer at low fire is at a higher number (as in the image above) than when at high fire (pointer is near 0).

2. Disconnect and lock out the power.

CAUTION! - Make sure power is disconnected and locked outbefore removing the Modulating Fuel Oil Valve.

Let the Heater cool before removing or replacing the Modulating Fuel OilValve.

Record pointer position

54

Jacketed Modulating Fuel Oil ValveFireboxHeaters

3. Loosen the indicated actuator arm screws.

4. Place a drip pan (or rag) under the valve.5. Disconnect the flare connections just above the gauge and the check valve

(indicated below).

6. Unscrew the gauge Tee from the pipe leading to the valve.

Actuator Arm

Loosen 2 screws

Flare Connection(top of gauge)

Flare Connection(top of check valve)

55

Parts Replacement

7. Support the valve, loosen the setscrew and remove the nuts from the U-bolt.

8. While supporting the valve, slide the actuator arm away and lower it with thecheck valve and gauge pipe it from the burner.

9. Remove the pipe for the gauge and the elbow for the check valve.10. Screw the pipe for the gauge and the elbow for the check valve into the

replacement valve using gas/oil resistant pipe thread compound on thethreads. Pay attention to the orientation of the check valve elbow.

11. Slide the replacement valve into the actuator arm and hold it in position withthe U-bolt with nuts/washers removed above.

12. Reinstall the tee with the gauge using gas/oil resistant pipe thread compoundon the threads. Pay attention to the orientation of the gauge.

Note: Wait at least 10 minutes for the pipe thread compound to set before continuing.13. Reconnect the fuel lines, tighten the U-bolt nuts and the set screw. Remove the

drip pan.14. Position the pointer to the position recorded for low fire then snug the

actuator arm screws.15. Remove the lockout and restore power.16. Start the heater and let it run through pre-purge. Check that the valve pointer

points to both the low and high fire positions recorded earlier. If fuel oilpressure is incorrect go to Fuel Oil System Bleeding on page 57.

17. Go to step 3 under Air Damper, Gas and/or Fuel Linkage on page 91 tocomplete the Modulating Fuel Oil Valve replacement.

Loosen Set Screw

U-bolt nuts

Pipe for Gauge

Check valve elbow

56

Jacketed Fuel Oil System BleedingFireboxHeaters

Fuel Oil System Bleeding1. Make sure all fuel oil system connections are tight.2. Place a drip pan (or drip rag) under the fuel oil return line next to the fuel oil

filter.3. Start the heater on fuel oil then slightly loosen the fuel oil return line

connection at the fuel filter letting any air escape.4. When no air is escaping and fuel oil is leaking out of the connection, tighten

the connection.5. Remove the drip pan and clean up any spilled fuel oil.

Burner Fuel Oil Ignition TransformerCAUTION! - Make sure power is disconnected and locked outbefore removing or replacing the Burner Fuel Oil IgnitionTransformer.

Let the Heater cool before removing or replacing the Burner Fuel Oil Igni-tion Transformer.

1. Remove the cover over the electrical connections, label then disconnect thewiring. Disconnect the electrical conduit from the box and move it and itscable out of the way.

Burner Fuel Oil Ignition Transformer

Electrical Connection Access

57

Parts Replacement

2. Remove the heater back plate to access the transformer mounting nuts.

3. Unplug the two spark ignition wires then remove the transformer mountingnuts w/washers. Remove the transformer.

4. Install the replacement transformer using the nuts w/washers removed above.5. Plug in the fuel oil spark ignition wires.6. Reinstall the heater back plate

Heater Back Plate

Transformer mounting nuts

Fuel Oil Spark ignition wires

58

Jacketed Fuel Oil Ignition GunFireboxHeaters

7. Feed the wiring through the side of the transformer cover, reattach the conduitthen connect the wires to the transformer terminals. Reinstall the electricalcover.

8. Remove the lockout and restore power.9. Start the heater on fuel oil to confirm proper operation.

Fuel Oil Ignition GunCAUTION! - Make sure power is disconnected and locked outbefore removing or replacing the Fuel Oil Ignition Gun.

Let the Heater and cool before removing or replacing the Fuel Oil IgnitionGun.

Note: This procedure can also be used for servicing.

Gun Assembly1. Shut the fuel oil supply OFF and place a drip pan (or rag) under the fuel oil

gun connections.2. Remove the heater back plate and unplug the two ignition cables from the

transformer.

Unplug ignition cables

59

Parts Replacement

3. Disconnect the fuel lines flare connections where they enter the burner andremove the indicated bolt.

4. Remove the fuel oil gun assembly.Note: If individual components are being replaced see their respective instructions that

follow. ( See Ignition Electrodes on page 60 ) ( See Ignition Cables on page 62 )5. Check the replacement gun for proper spacing of the electrode tips and

spacing to the fuel oil nozzle. See Ignition Electrodes below for measure-ments.

6. Install the replacement fuel oil gun assembly, center the diffuser within thetunnel then bolt into place using the bolt removed above.

7. Reconnect the fuel lines and remove the drip pan.8. Remove the lockout and restore power.9. Start the heater on fuel oil to confirm proper operation.

Ignition Electrodes10. With the fuel oil gun assembly out, disconnect the cables from the ends of the

electrodes.11. Remove the diffuser. Loosen the clamp holding the electrodes to the fuel line

and remove the electrodes.12. Install the replacement electrodes and reinstall the diffuser. Tighten screws

just enough to hold the diffuser and electrodes while allowing movement.

Fuel Line Flare Connections

Fuel Oil Gun mounting bolt

60

Jacketed Fuel Oil Ignition GunFireboxHeaters

13. Adjust the electrode tips and diffuser as indicated:

14. Tighten the clamp and recheck the electrode adjustments.15. Plug the cables into the electrodes.16. Check that the diffuser is uniformly flat with approximately 1/4" to 5/16"

between the blades.17. Repeat from step 6.

5/16” from the tip of the Nozzle to the ark point 5/16” from the center of the Nozzle out (up in photo) to the Electrodes

5/16” from the tip of the Nozzle to the back of the Diffuser

1/16” gap between Electrodes

61

Parts Replacement

Ignition Cables18. With the fuel oil gun assembly out, disconnect the cables from the ends of the

electrodes.19. Remove the cable strain reliefs from the spacer bracket.

20. Remove the strain reliefs from the removed cables.21. Plug the replacement cables into the ignition electrodes then feed through the

spacer bracket.22. Install the strain reliefs onto the cables at the spacer bracket.23. Check that the diffuser is uniformly flat with approximately 1/4" to 5/16"

between the blades.24. Repeat from step 6.

Burner Blower MotorCAUTION! - Make sure power is disconnected and locked outbefore removing or replacing the Burner Blower Motor.

Let the Heater cool before removing or replacing the Burner Blower Motor.

1. On the blower motor, remove the cover over the electrical junction box, labelthe motor wiring then disconnect the wiring. Release the wiring strain reliefthen remove the wiring cable from the junction box.

CAUTION! - The blower motor/fan assembly is heavy. Use care in removing it.

Cable strain reliefs

62

Jacketed Burner Blower MotorFireboxHeaters

2. Remove all six flange nuts w/washers holding the motor/fan assembly to theburner and remove the assembly.

Note: When removing the assembly be careful not to damage the rubber coupling between the fan and the fuel oil pump (when equipped).

3. Mark the position of the fan on the motor shaft then remove the fan from themotor shaft. Measure the distance from the motor shaft end to the mark justmade and write it down.

4. Remove the motor from the burner mounting flange.5. Attach the replacement motor to the burner mounting plate.6. Measure from the end of the new motor’s shaft the distance written down

above and make a mark on the shaft. Position the fan at the mark on themotor shaft and tighten the fan mounting screws.

7. Place the assembly back onto the burner and reinstall the flange nuts w/washers.

Note: Be sure to properly align the fan shaft with the rubber coupling to the fuel oil pump (when equipped).

8. Reinstall the cable, reconnect the wiring then tighten the strain relief. Reinstallthe junction box cover.

9. Remove the lockout and restore power.10. Start the heater and verify the motor is rotating in the direction indicated on

the housing. Correct if necessary.11. Check for unwanted vibrations when the blower turns on - correct as

necessary.

Flange Nuts

Blower Motor


63

Parts Replacement

Burner Air Flow SwitchCAUTION! - Make sure power is disconnected and locked outbefore removing or replacing the Burner Air Flow Switch.

Let the Heater cool before removing or replacing the Burner Air FlowSwitch.

1. Loosen the air line nut and disconnect the air line from the switch.

2. Remove the cover over the electrical junction box, label the switch wiring thendisconnect the wiring. Disconnect the electrical conduit from the box andmove it and its cable out of the way.

3. Remove the screws holding the air flow switch in place and remove the switch.4. Position and install the replacement switch using the screws removed above

then reconnect the air line.5. Feed the wiring through the side of the electrical junction box and reattach the

conduit.

CAUTION! For steps 6 through 11 the exposed terminals below the pressureadjustment screw may have 110VAC present.6. Clip the switch wires together making sure that they cannot ground against

anything, since they will be powered with 110 volts during the adjustment.7. Put a continuity meter across the common and normally open terminals on

the air switch.8. Close the gas train checking cock. Remove the lockout and restore power.

Air line nut

Burner Air Flow Switch

64

Jacketed Burner Air Flow SwitchFireboxHeaters

9. Start the blower motor. The meter should read electrical continuity as soon asthe blower starts.

10. Disconnect the blower motor (blower lead wire or the wire which energizescoil of motor starter. Within 4 to 5 seconds after the blower motor is de-energized, the meter should indicate an open air flow switch circuit (no conti-nuity).

11. If the switch does not open in 4 to 5 seconds, readjust accordingly. Turn theair flow switch adjustment screw clockwise to shorten cut-off response time,and counter-clock-wise to lengthen cut-off response time.

12. Turn the burner power off. Remove the shorting clip from the two discon-nected wires and let them hang loose. (They will be powered with 110 volts, sodon’t let them ground out.)

13. Open the gas train checking cock. Turn the burner on. With the wires discon-nected, the burner should go into a purge cycle, although neither the ignitionnor the main fuel valve circuits will be energized.

Note: If they do energize, there is a wiring problem. Correct as required.14. Turn power off. Reconnect the air flow switch wires to the air flow switch

terminals. Restore power and place burner back into normal operation.15. Verify the burner started as expected then install the switch cover.

Pressure Adjustment Screw

CAUTION!Terminals may have 110VAC

65

Parts Replacement

Burner Gas Ignition TransformerCAUTION! - Make sure power is disconnected and locked outbefore removing or replacing the Burner Gas Ignition Trans-former.

Let the Heater cool before removing or replacing the Burner Gas IgnitionTransformer.

1. Remove the cover over the electrical connections, label the wiring thendisconnect the wiring. Disconnect the electrical conduit from the box andmove it and its cable out of the way.

2. Disconnect the gas spark ignition wire from the top of the transformer.3. Remove the heater back plate to access the transformer mounting nuts.

Burner Gas Ignition Transformer

Gas Spark Ignition Wire


Heater Back Plate

66

Jacketed Burner Gas Ignition TransformerFireboxHeaters

4. Remove the transformer mounting nuts w/washers and remove the trans-former.

5. Install the replacement transformer using the nuts w/washers removed above.6. Reinstall the heater back plate.7. Reconnect the gas spark ignition wire to the top of the transformer.8. Feed the wiring through the side of the transformer cover, reattach the conduit

then connect the wires to the transformer terminals. Reinstall the electricalcover.

9. Remove the lockout and restore power.10. Start the heater on gas to confirm proper operation.

Transformer mounting nuts

67

Parts Replacement

Gas Pilot AssemblyCAUTION! - Make sure power is disconnected and locked outbefore removing or replacing the Gas Pilot Assembly.

CAUTION! Turn the gas supply OFF with the Main Gas Cock valve on thegas train.

Note: Before removing the pilot housing from the blast tube mount make sure that alignment marks are present.

1. Disconnect the ignition wire from the gas pilot transformer and disconnectthe tubing connection from the gas pilot assembly.

2. Mark the position of the Pilot Mounting Plate against the blast tube thenremove the indicated mounting screws.

3. Loosen both the indicated screw and setscrew then remove the assembly fromthe blast tube (the assembly is shown already removed from the blast tube forclarity).

Ignition Wire – Transformer Connection

Gas Pilot Connection and Cable Tie

Mounting Screws

Loosen screw and setscrew

Alignment Marks

68

Jacketed Burner Gas Ignition TransformerFireboxHeaters

4. Reverse the procedure making sure the clip on goes on the inside of the blasttube to hold the front end of the assembly in place. Make sure to line up thealignment marks before tightening the screws and setscrew.

5. Remove the lockout and restore power.6. Start the heater on gas to confirm proper operation.

Ignition Electrode1. Remove the clamp screw and clamp then remove the electrode.

2. Install the replacement electrode and adjust the electrode distance from theopen end and the spark gap then tighten the clamp screw.The spark gap between the electrode and the outside radius of the gas pilot

Clip - goes on inside of blast tube

Pilot Mounting Plate - goes on outside of blast tube

Clamp screw

Electrode

69

Parts Replacement

assembly should be 1/16" - 3/32". DO NOT set the spark to arc against thepilot head nozzle.

3. Reinstall the assembly following the steps under Gas Pilot Assembly above.

Ignition Cable1. Unplug the cable from the back of the electrode and pull out through the

strain relief.

2. Reinstall the assembly following the steps under Gas Pilot Assembly above.


2 15/16"Air Hole


Pilot Orifice



Air Hole


Pilot Orifice

3 1/16"


Strain relief

Cable

70

Jacketed UV ScannerFireboxHeaters

UV ScannerCAUTION! - Make sure power is disconnected and locked outbefore removing or replacing the UV Scanner.

Let the Heater cool before removing or replacing the UV Scanner.

1. Note the route of the UV Sensor’s cable then remove the cable ties holding thecable (be sure to note how the excess cable is coiled).

2. Open the PowerFlame terminal box and locate terminals S1 and S2.

3. Note which color of wire is connected the which terminal then disconnect theUV Scanner wires and pull the cable out the conduit connector.

Terminals S1 & S2Scanner connects to RIGHT terminals

Cable enters here

71

Parts Replacement

4. Remove the UV Scanner from the burner.

5. Install the replacement UV Scanner and feed its cable through the conduitconnector.

6. Connect the wires to terminals S1 and S2 in the PowerFlame terminal box.Note: Newer scanners also include a ground wire - be sure to connect it to the ground

connection in the terminal box.7. Route and cable tie the cable as noted in step 1 and coil the excess cable so it

doesn’t get caught/damaged in moving parts.8. Remove the lockout and restore power.9. Start the heater on gas to confirm proper operation.

UV Scanner

72

Jacketed UV ScannerFireboxHeaters

Level ControlCAUTION! - Make sure power is disconnected and locked outbefore removing or replacing the Level Control.

Let the Heater cool before removing or replacing the Level Control.

Place a drip pan under the Level Control to catch up to 5 gallons of heat transferfluid from the control’s plumbing.

1. Drain all the heat transfer fluid out of the expansion tank.2. Remove the upper cover from the Level Control.3. Locate, label and disconnect the electrical connections going into the conduit.

Remove the conduit nut and pull the conduit with wiring away from the levelcontrol.

4. Make sure to have a drip pan positioned then unscrew the Level Control fromthe expansion tank.

5. Reverse the procedure to install the replacement Level Control using gas/oilresistant pipe thread compound on the threads. Be careful to not to damagethe float.

6. Remove the lockout and restore power.7. Start the heater and monitor the level control signal.

Upper Cover

Conduit

Unscrew Level Control from here

73

Parts Replacement

Level Control SwitchCAUTION! - Make sure power is disconnected and locked outbefore removing or replacing the Level Control Switch.

Let the Heater cool before removing or replacing the Level Control.

1. Remove the upper cover from the Level Control.2. Disconnect the switch electrical connections and spring.3. Remove the switch mounting screw and remove the switch.

4. Reverse the procedure to install the new switch. Note that the switch wires leftto right in the image go to terminals 4, 5 & 6 respectively.

5. Remove the lockout and restore power.6. Start the heater and monitor the level control signal.

Electrical Connections

Spring

Mounting Screw

74

Jacketed Level Control SwitchFireboxHeaters

Circulating Motor/Pump CouplingCAUTION! - Make sure power is disconnected and locked outbefore removing or replacing the Motor Pump Coupling.

1. Remove the cover from the coupling cover between the motor and pump.2. If the entire coupling is being replaced, mark the position of the coupling on

both the motor and pump shafts.

Note: Normally only the sleeve is replaced unless a flange is damaged.3. Loosen the set screws on one flange and slide it away from the other enough

to remove the sleeve. Remove the sleeve.Note: If only the sleeve is being replaced, skip to step 8.

4. Slide the flange from above off of its shaft. As the flange key is exposed,remove and set it aside.

5. Loosen the set screws on the other flange and remove it. Remove its key andset it aside as it is exposed.

6. Place one of the replacement flanges onto a shaft, position its key then slide itover the key. Align it with the mark made above then snug its set screws.

7. Slide the remaining flange onto the other shaft, position its key and slide itover the key far enough to place the sleeve between the two flanges.

8. Position the sleeve between the flanges then slide the free flange barely againstthe sleeve and aligned with the mark from above. Snug its set screws.

9. Continue to the Circulating Motor/Pump Coupling Alignment on page 76.

Flange

FlangeSleeve

75

Parts Replacement

Circulating Motor/Pump Coupling AlignmentCAUTION! - Make sure power is disconnected and locked outbefore aligning the Motor/Pump Coupling.

Note: Inspect the existing sleeve to ensure there are no obvious equipment issues that could lead to a premature failure of a replacement sleeve. For example, if the serrations are worn off the old sleeve, there could be issues with misalignment. If the old sleeve is torn, particularly a diagonal tear in the sleeve, this could indicate the coupling is being subjected to an over torque condition. These issues need to be corrected prior to placing the equipment back in service.

1. Measure the coupling width at the outside of the flanges (see figure below) atseveral places around the coupling. All measurements should be the equal.

Note: Measurements that are not equal may indicate that the motor and pump shafts are not parallel to one another (tilted). Check the shafts to be parallel to the frame then correct the item that is not parallel using shims.

Equ

al di

stan

ce

76

Jacketed Circulating Pump MotorFireboxHeaters

2. Lay a straight edge across the top of the flanges and note the space betweenthe straight edge and the second flange. This parallel misalignment should beminimal.

Note: If the parallel misalignment is too great shim the lower item (motor or pump) to correct.

CAUTION! If the surfaces are not parallel excessive vibration may result. ContactCEI for assistance.3. Tighten the coupling set screws and repeat from step 1.4. Reinstall the coupling cover and remove the drip pan (if placed).5. Remove the lockout and restore power.6. Start the circulating pump (motor) and check for unwanted vibrations -

correct as necessary.

If the circulating pump motor was replaced verify the motor is rotatingin the direction indicated on the housing. Correct if necessary.

Circulating Pump MotorCAUTION! - Make sure power is disconnected and locked outbefore removing or replacing the Circulating Pump Motor.

1. Remove the cover from the coupling cover between the motor and pump.2. Remove the cover over the electrical junction box, label the motor wiring then

disconnect the wiring. Release the wiring strain relief then remove the wiringcable from the junction box.

Note space

77

Parts Replacement

CAUTION! - Motors are heavy and may require a mechanical lift to remove andplace on the heater assembly.3. Mark the position of the motor then loosen and remove the mounting bolts

holding the motor in place. Remove the motor making sure to note theposition of any shims. Set the shims aside.

4. Mark the position of the coupling on the motor shaft then loosen its setscrews and remove the coupling and coupling key. Measure the distance fromthe motor shaft end to the mark just made.

5. On the replacement motor1, place a mark the distance from the end of themotor shaft measured above. Slide the coupling onto the shaft making sure toproperly position the key and align it with the mark on the shaft. Snug but donot torque the coupling set screws.

6. Position the replacement motor and any removed shims on the heater andloosely bolt into place.

7. Reinstall the cable, reconnect the wiring then tighten the strain relief. Reinstallthe junction box cover.

8. Go the Circulating Motor/Pump Coupling Alignment on page 76.

Circulating PumpCAUTION! - Make sure power is disconnected and locked outbefore removing or replacing the Circulating Pump.

Let the Heater and Heat Transfer Fluid cool before removing or replacingthe Circulating Pump.

1. Close the Heat Transfer Fluid Isolation, Supply and By-pass valves.2. Place a drip pan under the circulating pump - a significant amount of Heat

Transfer Fluid will leak out of the pump and surrounding plumbing when thepump is removed.

3. Remove the cover from the coupling cover between the motor and pump.

CAUTION! - Pumps are heavy and may require a mechanical lift to remove andplace on the heater assembly.4. Mark the position of the pump then loosen and remove the mounting bolts

holding the pump in place. Remove the pump making sure to note theposition of any shims. Set the shims aside.

1. If the replacement motor IS NOT an exact replacement, align the end of the flange (serration side) with the end of the motor shaft.

78

Jacketed Electrical Components (Control Box)FireboxHeaters

5. Mark the position of the coupling on the pump shaft then loosen its set screwsand remove the coupling and coupling key. Measure the distance from thepump shaft end to the mark just made.

Note: Before installing the replacement pump be sure to remove all dust plugs from the pump. Check all possible locations.

6. On the replacement pump2, place a mark the distance from the end of thepump shaft measured above. Slide the coupling onto the shaft making sure toproperly position the key and align it with the mark on the shaft. Snug but donot torque the set screws.

7. Position the replacement pump with new flange gaskets and any removedshims on the heater and loosely bolt into place.

8. Go the Circulating Motor/Pump Coupling Alignment on page 76.

Electrical Components (Control Box)CAUTION! - Make sure power is disconnected and locked outbefore removing or replacing any Electrical Component.

Note: Certain electrical components contain settings and/or programming that must be set before using the component. When a replacement is ordered from CEI the settings and/or programming are pre-set for your system with the exception of some site specific settings. Ordering these components from another vendor may require additional resources to set or program the component.

1. When a component to be replaced has wiring connected to it, label the wiringas to its corresponding connection then disconnect the wiring.

2. Remove the component.Note: Depending on the specific component, the component may be plugged in, screwed in,

etc. Use the correct tool(s) to remove it.3. Reverse the above to install the replacement component. For site specific

settings see the indicated components listed below:• Honeywell UDC1200 Modulating Temperature Controller on page 80• Honeywell UDC120L High Temperature Limit Controller on page 83

4. Remove the lockout and restore power.

2. If the replacement pump IS NOT an exact replacement, align the end of the flange (serration side) with the end of the pump shaft.

79

Parts Replacement

Honeywell UDC1200 Modulating Temperature ControllerCAUTION! - Make sure power is disconnected and locked outbefore removing or replacing the Honeywell UDC1200 Modu-lating Temperature Controller.

.

Note: The Honeywell UDC1200 Modulating Temperature Controller is pre-programmed to the values listed in the tables below when ordered from CEI.

There are two distinct UDC1200 areas to program; Configuration and Setup.Configuration is programmed first.

Note: The controller automatically returns to the Operator mode after 2 minutes if no buttons are pressed.

ConfigurationNote: It is important to know this procedure in case of loss of program due to power surges.


2. With power applied to the unit, press and hold then press to

enter the Select mode (SLCt on the lower display).

3. Use or to scroll the upper display until it shows Conf then

press .

4. Use or to adjust the upper display for a value of 20 (the

default unlock code for configuration) then press .

5. Press to display the desired Configuration Parameter on the lower

80


display then use or to set the upper display value. Press

to accept and enter the parameter value.

Note: If the Man/Auto button is not pressed the value returns to the original value.6. Repeat step 5 until all Configuration Parameter values match the values in the

following table:

7. Press two times to exit Configuration.

SetupNote: It is important to know this procedure in case of loss of program due to power surges.

Configuration must be completed before starting Setup.



2. Use or to scroll the upper display until it shows SetP then

press .

Note: While the UDC1200 is in Setup the Man indicator is lit.

Lower Display Function

Upper Display Value


Upper Display Value

InPt Input Type JF AHY2 Alarm 2 Hysteresis 1.0

ruL Scale Range Upper Limit

450.0 LAEn Loop Alarm diSA

rLL Scale Range Lower Limit

20.0 Inhi Alarm Inhibit nonE

CtYP Control Type SnGL USE1 Output 1 Usage Pri

CtrL Primary Outut Control Action

rEu tyP1 Linear Output 1 Range 4_20

ALA1 Alarm 1 Type dE USE2 Output 2 Usage A2_d

dAL1 Derivative Alarm 1 Value

25.0 USE3 Ouptup 3 Usage A1_r

AHY1 Alarm 1 Hysersis 35.0 diSP Display Strategy 2

ALA2 Alarm 2 Type dE CLoc Configuration Lock Code

20

dAL2 Derivative Alarm 2 Value

15.0

81

Parts Replacement


default unlock code for setup) then press .

4. Press to display the desired Setup Parameter on the lower display then

use or to set the upper display value.

Note: Unlike configuration, pressing Setup after changing a value enters that value and displays the next parameter.

5. Repeat step 4 until all Setup Parameter values match the values in thefollowing table:

6. Press and hold then press to return to the Select mode.

Lower Display Function Value Lower

Display Function Value

FiLt Input Filter Time Constant

0.0 dAL 1 Derivative Alarm 1 Value

25.0

OFFS Process Variable Offset 0.0 AHY 1 Alarm 1 Hysteresis 35.0

Current Power Levels 0 dAL 2 Derivative Alarm2 Value

15.0

Pb_P Primary Proportional Band

10.0 AHY 2 Alarm 2 Hysteresis 1.0

ArSt Integral Time 5.00 APt Auto Pre-Tune diSA

rAtE Derivative Time 1.00 PoEn Auto/Manual Control Selection

EnAb

biAS Manual Reset 0 SPr Show Set Point Ramp Adjust

diSA

SPuL Set Point Upper Limit 450.0a

a. These values are automatically populated from the corresponding values in configuration

rP Set Point Ramp Value (leave blank)

SPLL Set Point Lower Limit 20.0a SP Set Point Value 350.0

OPuL Primary Output Power Level

100 SLoc Setup Lock Code 10

82


Honeywell UDC120L High Temperature Limit ControllerCAUTION! - Make sure power is disconnected and locked outbefore removing or replacing the Honeywell UDC120L HighTemperature Limit Controller.

Note: The Honeywell UDC120L High Temperature Limit Controller is pre-programmed to the values listed in the tables below when ordered from CEI.

There are two distinct UDC120L areas to program; Configuration and Setup.Configuration is programmed first.

Note: The controller automatically returns to the Operator mode after 2 minutes if no buttons are pressed.

ConfigurationNote: It is important to know this procedure in case of loss of program due to power surges.




3. Use or to scroll the upper display until it shows ConF then

press .


default unlock code for configuration) then press .

5. Press to display the desired Configuration Parameter on the lower

83

Parts Replacement

display then use or to set the upper display value. Press

to accept and enter the parameter value.

Note: If a changed parameter value is blinking the Reset button must be pressed or the value will return to the original value.

6. Repeat step 5 until all Configuration Parameters match the values in thefollowing table:


SetupNote: It is important to know this procedure in case of loss of program due to power surges.

Configuration must be completed before starting Setup.

1. If necessary, press and hold then press to enter the Select

mode (SLCt on the lower display).

2. Use or to scroll the upper display until it shows SEtp then

press .

Note: While the UDC120L is in Setup the Setup LED indicator is lit.


unlock code for setup) then press .


Upper Display Value


Upper Display Value

InPt Input Type JF AHY1 Alarm 1 Hysteresis 1

ruL Scale Range Upper Limit

450.0 ALA2 Alarm 2 Type P_Lo

rLL Scale Range Lower Limit

20.0 PLA2 Low Alarm 2 Value 20

OFFS Process Variable Offset 0 AHY2 Alarm 2 Hysteresis 1

CtrL Limit Action Hi USE2 Output 2 Usage A1_d

SPuL Setpoint Upper Limit 450.0 diSP Display Strategy EnAb

ALA1 Alarm 1 Type P_Hi Cloc Configuration Lock Code

20

PhA1 High Alarm 1 Value 450.0

84

Jacketed Modulating MotorFireboxHeaters

4. Press to display the desired Setup Parameter on the lower display then

use or to set the upper display value.

5. Press to accept the parameter and display the next parameter.

6. Repeat from step 4 until all Setup Parameters match the values in the followingtable:


Modulating MotorLet the Heater cool before removing or replacing the Modulating Motor.

CEI suggests that the Modulation Motor and its internal Resistor Board bereplaced together.

1. If not already present, mark both the low and high fire positions for the airdamper openings, both right and left linkages and the modulating fuel oil valvepointer.

CAUTION! - Make sure power is disconnected and locked outbefore removing or replacing the Modulating Motor.

Lower Display Function Value Lower

Display Function Value

SP Setpoint Value 450.0 AHY1 Alarm 1 Hysteresis 1.0

hySt Limit Hysteresis 1.0 PLA2 Low Alarm 2 Value 20.0

fiLt Input Filter time Constant

2.0 AHY2 Alarm 2 Hysteresis 0.1

PhA1 High Alarm 1 Value 450.0 SLoc Setup Lock Code 10

85

Parts Replacement

2. Remove the electrical connection cover, label all the wiring then disconnectthe wiring. Remove the conduit nuts then remove the wiring cable from themotor enclosure.

3. DO NOT loosen any linkage bolts or screws. Loosen the 4 square head bolts(2 on each side) on the modulating motor shaft extensions just enough toallow the extensions to slide then slide each shaft extension off the motorshafts.

4. Remove the 4 mounting bolts/nuts/washers holding the modulating motorthen remove the motor.

If possible, replace the resistor board and adjust the cams on a workbench.• See Workbench on page 87 for workbench instructions.• See On Heater on page 89 for on heater instructions.

Electrical connection cover

Loosen only the motor shaft extension square head bolts

86


Workbench1. When installing a new resistor board, set its DIP switches to match those of

the removed motor’s resistor board.

Note: To verify the DIP switches are correctly set measure the resistance from W+ to R and R+ and B. Resistance should be 66.5Ω and 237Ω respectively.

2. Remove the new modulating motor cover and install the resistor board.3. When the resistor board is installed, connect the brown wires from the trans-

former to T1 & T2 on the resistor board then set the board switches the sameas those on the removed motor.

If the resistor board is not installed at this time connect the brown wires fromthe transformer to the T1 & T2 lugs.

CAUTION! Possibility of electrical shock - all connections may and all trans-former leads will be live. Use proper precautions for steps 4 through 8.

Resistor Board Installed No Resistor Board

Old Style Dip Switches New Style Dip Switches

Switch positions are the same - numbering differs

T1 & T2 connections

DIP switches

T1 lug

T2 lug

87

Parts Replacement

4. Connect 110VAC to the motor’s transformer input leads then apply power.When power is applied the motor will drive to the low fire position (if notalready there).

5. With the motor at the Low Fire position, adjust the outer cam so that theindicated high point of the cam is actuating the low fire switch.

6. Remove power, place a jumper between R– and B. Reapply power to drive themotor to the High Fire position.

7. With the motor at the High Fire position, adjust the inner cam so that theindicated high point of the cam is actuating the high fire switch.

8. Remove power and remove the jumper.9. Repeat steps 4 through 8 to verify the cams actuate their switches at the proper

positions. Disconnect the external power.

Resistor Board Installed No Resistor Board

Transformer Input Leads

Outer Cam

Inner Cam

Switch forLOW

fire signal

Switch forHIGH

fire signal

Outer cam High point

Inner cam High point

R- B

R- lug

B lug

88


10. Using the bolts/nuts/washers removed earlier, install the new modulatingmotor.

11. See Air Damper, Gas and/or Fuel Linkage on page 91 to complete themodulating motor replacement.

On Heater1. Note the removed motor’s resistor board switch settings and wire connections:

• When installing a new resistor board, set its DIP switches to match thoseof the removed motor’s resistor board

Note: To verify the DIP switches are correctly set measure the resistance from W+ to R and R+ and B. Resistance should be 66.5Ω and 237Ω respectively.

• If the existing resistor board is being reused, disconnect the wiring andremove it from the defective motor.

2. Install the resistor board in the new motor and connect all the wires exceptthe wire to the W+ terminal.

3. Using the bolts/nuts/washers removed earlier, install the new modulatingmotor.

Old Style Dip Switches New Style Dip Switches

Switch positions are the same - numbering differs

Resistor Board Switches

Brown wires from transformer to T1 & T2

Leave the W+ wire disconnected

89

Parts Replacement

CAUTION! Possibility of electrical shock - all terminal connections may and alltransformer leads will be live. Use proper precautions for steps 4 through 11.

4. Route the wiring cable into the new motor and secure the conduit with theconduit nuts removed earlier.

5. Verify that the main fuel valves are closed then apply power to the burner –the burner will go through a prepurge cycle and stop (locked out) in a low fireposition.

6. With the motor at the Low Fire position, adjust the outer cam so that theindicated high point of the cam is actuating the low fire switch.

7. Remove power, place a jumper between R– and B. Reapply power to drive themotor to the High Fire position.

8. With the motor at the High Fire position, adjust the inner cam so that theindicated high point of the cam is actuating the high fire switch.

9. Remove power and remove the jumper.10. Repeat steps 5 through 9 to verify the cams actuate their switches at the proper

positions.11. Connect the W+ wire to the W+ terminal then install the motor cover.12. Continue to Air Damper, Gas and/or Fuel Linkage.

Outer Cam

Inner Cam

Switch forLOW

fire signal

Switch forHIGH

fire signal

Outer cam High point

Inner cam High point

R- B

90

Jacketed Air Damper, Gas and/or Fuel LinkageFireboxHeaters

Air Damper, Gas and/or Fuel Linkage1. With the burner locked out and the modulating motor at the low fire position

slide the motor shaft extensions onto the motor shafts paying attention to thelinkage marks made earlier. Because the motor shafts are square the shaftextensions will properly align onto the motor shafts (when the shaft extensionbolts were only loosened). Tighten the shaft extension bolts.

2. Turn the burner on and let it advance to the main flame light off position.

Note: Perform steps 3 through 5 using the fuel source normally used to operate the heater. On combination systems, when no changes have been made to the control linkage, the linkage for the other fuel should not need adjustment.

3. With the burner in the low fire position, check for a fuel/air ratio low firesettings of:

• 7 - 9% CO2 and little or no3 CO on Gas.• 8 - 10% CO2 and #0 - #2 Smoke Reading on Fuel.Note: If an adjustment is necessary, make the adjustment and mark the linkage at the new

settings.4. Increase the firing rate to the midway point. Again check for a fuel/air ratio of:

• 7 - 9% CO2 and little or no3 CO.• 9 - 11% CO2 and #0 - #2 Smoke Reading on Fuel.Note: If an adjustment is necessary, make the adjustment and mark the linkage at the new

settings.5. Increase the firing rate to high fire position and repeat the test done for the

mid point adjustment. Check for fuel/air ratio of:• 8½ - 10% CO2 and little or no3 CO on Gas• Approximately 12½% CO2 and no more than #2 Smoke Reading on Fuel.Note: If an adjustment is necessary, make the adjustment and mark the linkage at the new

settings.

Gas/Air or Fuel/Air Mixture AdjustmentsCAUTION! The following procedures should only be performed by individualsqualified and trained to perform the adjustments.

The adjustments that follow are condensed. For complete instructions consult themanufacturer’s manual.

91

Parts Replacement

Gas Burner Instructions1. Check all linkages2. Close the main, checking and pilot gas cocks.3. Install required system measuring devices:

• Appropriate flame signal meter to the flame safeguard control.• U-Tube Manometer or 0-10" W.C. gauge in the pilot test tee port.• Stack thermometer and CO2 or O2 analyzer sample line to the breaching.• Draft gauge or inclined manometer to the combustion chamber test point.• 0-35" W.C. gauge main gas pressure regulator inlet.

4. Slowly open the main gas cock in order to determine that the incoming gaspressure is within the specified limits of the main and pilot gas pressureregulators, automatic fuel valves and gas pressure switches.

5. Disconnect the pilot line at the inlet to the pilot gas pressure regulator andpurge air from the pilot gas line. After the air is purged from the gas supplysystem, close the pilot cock and reconnect the pilot line. Leave the pilot cockclosed.

Note: It is strongly recommended that an automatic gas valve bubble leak test be performed in accordance with the gas valve manufacturer’s instructions periodically in order to ensure that the valve is functioning according to the manufacturer’s specifications. It is also suggested that the test be conducted during a normal prepurge burner operation.

6. If necessary, set the air dampers approximately ¼" open. With both pilot andleak test gas cocks closed, open the main gas cock to allow the low gaspressure switch to make its circuit. With the control switch in the OFFposition, apply power to the burner through the main burner disconnectswitch. Switch the burner panel ON/OFF switch to the ON position momen-tarily to determine that the blower rotation is correct.

7. Restart the burner. With the pilot gas cock closed, the burner goes through ablower prepurge period. After the prepurge the gas pilot ignition transformeris energized although no pilot will be established. At no time should there beany flame signal reading nor should the main gas valve attempt to open. At theend of the pilot trial for ignition and blower purge period the flame safeguardcontrol should shut the system down in a safety lock-out mode. The safetylock-out mode requires a manual reset to the flame safeguard control to restartthe burner.

8. Wait three minutes, reset the flame safeguard control safety switch and openthe pilot gas cock. When the blower prepurge period ends and the burner isenergized, set the flame safeguard timer Stop/Run switch to Stop. While thepilot is on make adjustments as required. Recycle the burner several times tomake certain pilot operation is reliable.

92

Jacketed Gas/Air or Fuel/Air Mixture AdjustmentsFireboxHeaters

9. Initial Spark Pickup Test. With the pilot gas cock closed, the burner goesthrough a blower prepurge period. After the prepurge the gas pilot ignitiontransformer will be energized although no pilot will be established. At no timeshould there be any flame signal reading nor should the main gas valve attemptto open. At the end of the pilot trial for ignition and blower purge period theflame safeguard control should shut the system down in a safety lock-outmode. The safety lock-out mode requires a manual reset to the flamesafeguard control to restart the burner.

10. Once the pilot adjustments are complete set the timer switch to the Runposition to allow the start-up sequence to proceed to the automatic gas valveenergizing position.

11. When the main automatic gas valve begins to open, slowly open the checkinggas cock to light off the main flame. The main flame should light immediately.

12. Adjust the burner as necessary to provide smooth ignition of the main flame.If the flame signal drops significantly when the main automatic gas valveopens, slightly increase the pilot gas pressure to attain a stable flame signalvalue.

13. Verify that the butterfly valve is in the low fire position. To verify observe theend of the metering valve shaft, the slot in the end of the shaft indicates theposition of the valve. If low fire the valve should be nearly closed.

14. Turn the burner on and let it advance to the main flame light off position.Take action as necessary to hold the linkage at the low fire position by electri-cally disconnecting the modulating motor.

Note: It is suggested that the factory settings be noted and marked on the linkage prior to proceeding with final adjustment.

15. With the burner in the factory set low fire position, adjust air and fuel linkageto good fuel/air ratio low fire settings (7 - 9% CO2, little or no3 CO). If thelinkage position is different from the factory settings, mark the linkage at thenew settings.

16. Increase the firing rate to the midway point. Set the fuel/air ratios to achievegood combustion values (7-9% CO2, little or no3 CO). Again, if the linkageposition is different from the factory settings, mark the linkage at the new midfire position.

17. Increase the rate to high fire position and repeat the test done for the midpoint adjustment. Results should range in the area of 8½ to 10% CO2, withlittle or no3 CO. The metering device setting and air damper openings shouldbe marked and noted to obtain high fire reference points if different from thefactory settings.

3. Although Underwriters Laboratories permits higher readings of CO (Carbon Monox-ide), it is desirable to obtain readings between 0 and 100 PPM, depending on local codes and burner manufacturer’s recommendations

93

Parts Replacement

18. Operate the modulating lever arm on the modulating motor through the threepreviously referenced points. Minor setting modifications may be required toensure that the reference points are acquired.

19. Tighten (finger tight) the hex bolt to the linkage rod at the swivel on themodulating motor driver arms and run the motor through its full travel toensure that the linkage is free and that limits on the metering device and airdampers are not exceeded.

20. Determine that the required gas input rate is being achieved by clocking thegas flow at the gas meter.

21. Intermittently operate the burner until the heat transfer fluid indicates anincrease in temperature.

22. Tighten all linkages and permanently mark the settings. 23. Check the limit control as follows:

a. Run the burner until the limit control settings have been reached.b. Set the controls so that the burner goes to the low fire position before the

operating limit control turns the burner off (the burner should turn offwhen the set temperature is reached).

c. After a temperature drop the burner should restart automatically.24. Set and check operation of:

• Low and high gas pressure switches.• All burner and heat exchanger controls and operating devices.• Blower Combustion Air Flow Switch.

Fuel Oil Burner Instructions1. Check all linkages2. Install oil pressure and vacuum gauges. Check the fuel oil suction line to be

sure the manual valve is open. Check the fuel oil filter for tightness.3. Install required systems measuring devices:

• Appropriate flame signal meter to the flame safeguard control• Stack thermometer, CO2 and Smoke Tester sample line in the breaching• Draft gauge to the combustion chamber test point

4. With the burner panel control switch in the OFF position, apply power to theburner through the main burner disconnect switch. Switch the burner panelON/OFF switch to the ON position momentarily to determine that theblower motor is running in the right rotation.

5. If necessary, set the air damper approximately ¼" open and start the burner.When first started the ignition circuit energizes after the blower prepurgeperiod finishes and all limit and other interlock circuits are closed. Set theflame safeguard timer Stop/Run test switch in the Stop position thus causingthe ignition timing sequence to stop. There should be no evidence of a flamesignal reading nor should the main fuel oil solenoid valve attempt to open.

94

Jacketed Gas/Air or Fuel/Air Mixture AdjustmentsFireboxHeaters

6. The ignition spark and main fuel oil solenoid valve are energized at the sametime. As soon as the fuel oil flame is detected by the flame scanner, theignition spark is de-energized.

7. Either remove the flame scanner from its sight pipe or electrically disconnectthe main fuel oil solenoid valve and start the burner. The flame safeguardcontrol will not detect any flame and goes into a safety lockout mode requiringmanual reset of the flame safeguard safety lockout switch. (should a pressurereading occur before the main fuel oil valve is programmed to open it isindicating that the main fuel oil valve is leaking.)

Note: The modulating motor is connected by linkage to the air inlet dampers and the modulating fuel oil valve located in the oil nozzle return line. The fuel metering valve controls the fuel input quantity from low to high fire.

8. Verify that the modulating fuel oil valve is at the low fire position. To verifyobserve the pointer on the metering valve shaft. The pointer must be pointingnear the #6 or #7 position on the dial. As the burner runs from low to highfire the pointer moves from the low fire setting towards the 0 position on thedial.

9. Turn the burner on and let it advance to the main flame light off position.Take action as necessary to hold the linkage at the low fire position by electri-cally disconnecting the modulating motor.

Note: It is suggested that the factory settings be noted and marked on the linkage prior to proceeding with final adjustment.

10. With the burner in the factory set low fire position, adjust air and fuel linkageto good fuel/air ratio low fire settings (8 - 10% CO2 and #0 - #2 smokereading). If the linkage position is different from the factory settings, mark thelinkage at the new settings.

11. Increase the firing rate to the midway point. Set the fuel/ air ratios to achievegood combustion values (9 - 11% CO2 and #0 to #2 smoke reading). Again, ifthe linkage position is different from the factory settings, mark the linkage atthe new mid fire position.

12. Increase the rate to the high fire position and repeat the tests done for themid-point adjustment. Results should be in the area of 12½% CO2 and nomore than #2 smoke. The metering device setting and air damper openingsshould be marked and noted to obtain high fire reference points if differentfrom the factory settings.

13. Operate the modulating lever arm on the modulating motor through the threepreviously determined reference points. Minor setting modifications may berequired to ensure that the reference points are acquired.

95

Parts Replacement

14. Tighten (finger tight) the hex bolt to the linkage rod at the swivel on themodulating motor driver arms and run the motor through its full travel toensure that linkage is free and that the limits on the metering device and airdampers are not exceeded.

15. Intermittently operate the burner until the heat transfer fluid indicates anincrease in temperature.

16. Tighten all linkages and permanently mark settings.

32. Check the limit control as follows: a. Run the burner until the limit control settings have been reached.b. Set the controls so that the burner goes to the low fire position before the

operating limit control turns the burner off (the burner should turn offwhen the set temperature is reached).

c. After a temperature drop the burner should restart automatically.17. Set and check operation of:

• Low Fuel Oil Pressure Switch.• All burner and heat exchanger controls and operating devices.• Blower Combustion Air Flow Switch.

96


Section 6: Parts

Parts

98

JacketedO

verallFireboxH

eaters

99

g on heater size - refer to the

Description - page #

Burner, starting on page 106

40

Miscellaneous Parts on page 114

Expansion Tank - Contact CEI

Jacketed Fire Box - Contact CEI

Heat Exchanger - Contact CEI

Overall

Side View

Top View

FireBox End View

1 234 5

6

7

8

9

10

1112

13

14

15

16

17

18 19

20

Item part numbers can differ dependinillustration on the indicated page.

# Description - page # #

1 Control Box - page 100 112 Drain Pipe Assembly on page 1023 Fuel Filter Assembly on page 103 12-1

17-24-7

15-16Heat Transfer Fluid Plumbing on page 104

21

8 Circulating Pump Assembly on page 103

22

9-10 Sight Gauge on page 105 23

21

22

23

Front Panel

100 Control Box

more than 1)

tem size under Main Circuit

Illuminated)

Front Panel

Part Number Description (qnty if

0103328 UDC 1200 Temperature Controller0103330 UDC 120L Limit Controller0106260 Fireye BLL-510 Display0108352 110-130VAC LED Pilot Lamp0108347 Pilot Light Base - White0108363 2 Position Maintained Switch (4)0108371 Flush Black Push Button0108434a

a. This item activates the system main circuit breaker listed by sysBreakers on page 102.

Through the Door Operator0108678 2 Position Maintained Switch (Red,

Fireye BLL-510 Display

UDC 1200Controller

UDC 120LController

Thru the Door

2-PositionSwitch

2-PositionIlluminatedSwitch

Black PushButton

PilotLamp &Base

Operator

JacketedControl Box

FireboxH

eaters

101

s: UL or CSA. Heaters sold ine UL control box.

SA control box, these include:

Description

eye YP-138 Programmereye YB-110UVSC w/Amplifieriring Base for Amplifier/Chassis

nunciator Kitcludes chassis, base and connecting ble)eye 129-178-4 Remote Mounting Kitnunicator Basea

ely, this item is also part of Annunciator

erconnect Cablea

onnects chassis)

Internal Control Box Components

With minor exceptions, all CEI Jacketed Firebox Heaters utilize one of two control boxeCanada use the CSA control box while heaters sold elsewhere, including the U.S., use th

Most UL and CSA control boxes parts are identical and are listed below:• Fireye Components

• Other components:

CEI Jacketed Firebox Heater with a UL control box have some parts not included in a C

Item Part #

1 0106261 Fir2 0106259 Fir

Not Shown

0106262 W

3 0106263 An(inca

Not Shown

0106264 Fir60.2874.1 An

a. Available separatKit (0106263).

ED 580 Int(C

1

2

3

Part # Description

0108275 Relay, DIN Rail 2 C-Form Contacts0215007 Control Transformer0215038 Cover for Control Transformer

UL (only) Part Number Description

0101022 4A 1P Breaker0101170 3A fuse (2)0104054 Modular Double Fuse Holder


102 Components not previously listed vary from one CEI Jacketed Firebox Heater to the next.elp with these items.

D is the same regardless of

System

on page 100.

200, 2400, 1800

3600

4900

6300

200, 4900, 6300

800, 2400, 3600

1800, 2400

3600

1200

4900, 6300

CEI Part Number

1301006

Note: Items for speciality systems (i.e. non-standard voltage, etc.) are not listed. Contact CEI for h

rain Pipe AssemblyThe CEI Part Number for this itemheater size.

Category Description Part Number

Main Circuit Breakersa

a. These circuit breakers are externally controlled by the Thru The Door Operator (P/N 0108434) listed

30A Panel Mounted Breaker 0108439 1

40A Panel Mounted Breaker 0108433



Combo (motor) Starters 6.3~10A Panel Mount 0108418 1

2.5~4.0A Panel Mount 0108444 1

10~16A Panel Mount 0108449


1.6~2.5A Panel Mount 0108468


Item Description

1 ¾” Brass Gate Valve

1

JacketedFuel Filter A

ssemblyFireboxH

eaters

103

)

4900 6300

0302030A (20) 0302030A (20)1801004-SIHI

150600400-9010 6663000-6010

Fuel Filter Assembly

The CEI Part Numbers for these items are the same regardless of heater size.

Circulating Pump Assembly

The CEI Part Numbers for these items may vary depending on heater size

1

23

Item Description CEI Part Number

1 3/8”” Check Valve 13010312 Fuel Filter 15070013 Fuel Meter (optional) 4513267

#Description

Part Number (HP

1200 1800~2400 3600

1 - Motor 0302004A (5) 0302005A (7½) 0302007A (15)2 - Coupling 1801002-SIHI 1801003-SIHI3 - Circulating Pump 1506000 1506001 15060024 - Coupling Cover 6614000-2010 6622000-2010 66400

1

2

34


104 Heat Transfer Fluid Plumbing

6

emperature Heaters use Gate instead of Plug Valves where

indicatedr items match same size heater

~4900 6300

057 - 3” 1303058 - 4”

057 - 3” 1303058 - 4”

057 - 3” 1303058 - 4”

The CEI Part Numbers for these items may vary depending on heater size.

See Circulating Pump Assembly on page 103

1 2

3

4

5

14

#Description

Part Number - SizeHigh TValves

All othe

1200 1800 2400~4900 6300 2400

1 - Return Plug Valve 1303013 - 2” 1303015 - 3” 1303016 - 4” 13012 - H.O. Heater Pipe Thermometer 04020073 - Bypass Gate Valve 1303085 - 1” 1303094 - 1¼” 1303082 - 2”4 - Supply Plug Valve 1303013 - 2” 1303015 - 3” 1303016 - 4” 13015 - Bleeder Valve 15030266 - Isolation Plug Valve 1303014 - 2½” 1303015 - 3” 1303016 - 4” 1301

JacketedSight G

augeFireboxH

eaters

105

CEI Jacketed Firebox Heaters,

0

018

Sight Gauge

The CEI Part Number for the sight gauge is the same for the 1200 through 4900 series the 6300 heater uses a different sight gauge.

1

2

2

3

# DescriptionPart Number

1200~4900 630

1 - Sight Gauge (glass) 0401016 04012 - Sight Gauge Cock (pair) 04010103 - Temperature Gauge 0402005Sight Glass Rubber Gasket (not shown) - 2 required 0401011


106 Burner (blower side)r these items are the same

CEI Part Number

0102018-PFoid Valve 1305008-PF

0214002-PF0214004-PF

ccess) See page page 108r 0106130

1 2

3

45

The CEI Part Numbers foregardless of heater size.

Item Description

2 Air Flow Switch3 Gas Pilot Cutoff Solen4 Fuel Oil Transformer5 Gas Transformer6 Gas Pilot Assembly (a7 Fireye UV1A6 Scanne

The CEI Part Number for the Blower Motor (item 1) variesdepending on the size of the heater:

Heater Part Number - Horsepower

1200 03010030 - ¾HP1800~2400 03010005 - 1½HP3600~6300 Call for Part Number & HP

6

7

JacketedBurner (opposite blower)

FireboxH

eaters

107

Valve (item 5) andending on the size

3600

1301005_PF

1800~6300

1301029

Burner (opposite blower)Note: See pages 109 thru 112 for Gas Train Components

The CEI Part Numbers for these items are the sameregardless of heater size.


1 Fuel Solenoid (2) 15030112 0~600 Oil Pressure Gauge 0401020-PF3 0~200 Oil Pressure Gauge 04010204 Fuel Pump 1503011

The CEI Part Number for the Oil Check the Modulating Oil Valve (item 6) varies depof the heater:

Item Description 1200~2400

5 Modulating Oil Valvea

a. Call CEI for 4900~6300 part number

1301003-PF

Item Description 1200

6 Fuel Oil Check Valve 1301030-C10

1

2

3 4

1

5 6


108 Burner - Internal

2

1

2

3

Gas Pilot Assembly

Fuel Oil Nozzle and Ignitor Electrodes


Gas Pilot Assy 0614013-PF

1 Electrode 0208011-PF

2 Cable 0205002-PF1

Item Description CEI Part NumberFuel Oil Ignitor Gun Assy 060439-PF

1 Electrodes (pair) 0208008-PF2 Diffuser 009901-1253 Fuel Oil Nozzle See below

Cables (pair - not shown) 0205004Oil Screen (not shown) 2515031-L/C

Heater Size Nozzle Part Number

1200 (6 gph) 0612012

1800 (9.5 gph) 0612013-PF

2400 (12 gph) 0612014-PF

3600 (19.5 gph) 0612016

4900/6300 Call CEI

JacketedG

as TrainFireboxH

eaters

109

5

6

9

- Size

2" ¼”3/8“5 H2O

PropaneOrifice

1

Gas Train

1200~1800 Heaters

23

4

7 8

9

1

The CEI Part Numbers for these items may vary depending on heater size.

Orifice for Propane (Optional)

# - Description (Qnty if < 1)Part Number - Size

# - Description (Qnty if < 1) Part Number1200 1800

1 - Gas Cock Valve (2) 1302043 - 2” 6 - Gas Orifice Spring 0102114 -2 - Main Gas Regulator 0102012 - 2" 7 - Gas Pilot Ball Valve 0901021 -3 - Gas Actuator Valve 1304032 8 - Gas Pilot Regulator 0102007 - 4 - Gas Valve Body 1304031 - 2' 9 - Gas Pressure Gauge (2) 0401008 - 0~15 - Butterfly Valve 1304016 - 1¼” 1304014 - 2"

Part # - Size Heater

0102040 - 17/32” 12000102041 - 31/32” 1800

2400~3600 H

eaters

110 2400~3600 Heaters

5

6

9

1

PropaneOrifice

10

The CEI Part Numbers for these items may vary depending on heater size.# - Description (Qnty if < 1) Part Number - Size # - Description (Qnty if < 1) Part Number - Size

1 - Gas Cock Valve (2) 1302043 - 2” 7 - Gas Pilot Ball Valve (2) 0901021 - ¼”2 - Main Gas Regulator 0102012 - 2" 8 - Gas Pilot Regulator 0102007 - 3/8“3 - Gas Actuator Valve 1304032 9 - Gas Pressure Gauge (2) 0401008 - 0~15 H2O4 - Gas Valve Body 1304031 - 2' 10 - High Pressure Switch 01130575 - Butterfly Valve 1304014 - 2" 11 - Low Pressure Switch 01130586 - Gas Orifice Spring 0102114 - 2" Propane Orifice (optional) 0102042 - 25/32”

23

4

7 8

9

1 11

7

JacketedG

as TrainFireboxH

eaters

111

A

A

A – A

9

12

1

6

4900 Heater

* Indicates manufacturer part number

# - Description (Qnty if < 1) Part Number - Size # - Description (Qnty if < 1) Part Number - Size

1 - Gas Cock Valve (2) *980400 - 2½” 8 - Gas Pilot Regulator 0102007 - 3/8“2 - Main Gas Regulator *300900 - 2½” 9 - Butterfly Valve *M90030 - 2”3 - 17.5W ASCO G.C. Valve *281200 - 2½” 10 - Gas Orifice Spring 0102046 - 2½”4 - 13 Second ON/OFF Proof of Closure *190900 11 - Low Pressure Switch *1610005 - Proof of Closure Valve Body *194300 - 2½” 12 - High Pressure Switch *1611006 - Gas Pressure Gauge (3) 0401008 - 0-15” H2O Propane Orifice (optional) 0102047 - 1-1/16”7 - Gas Pilot Ball Valve *980030 - ¼”

12 3

4

5

6

7 8

10

1113

6

PropaneOrifice

6300 Heater

112 6300 Heater

10

11

PropaneOrifice

1

7

13

* Indicates manufacturer part number

# - Description (Qnty if < 1) Part Number - Size # - Description (Qnty if < 1) Part Number - Size

1 - Gas Cock Valve (2) *980450 - 3” 8 - Gas Pilot Ball Valve 0901021 - ¼”2 - Main Gas Regulator *301100 - 3" 9 - Gas Pilot Regulator 0102007 - 3/8“3 - Fast Opening Acuator *199000 10 - Butterfly Valve *273740 - 3”4 - Valve Body for 199000 *196500 - 3’ 11 - Gas Orifice Spring 0102114-3 - 3”5 - Proof of Closure Fast Opening Acuator *199010 12 - Low Pressure Switch *1610006 - Valve Body for 199010 *1997460 - 3” 13 - High Pressure Switch *1611007 - Gas Pressure Gauge (3) 0401074 - 0-15psi Propane Orifice (optional) 0102078 - 1-1/8”

1 2 3

4

5

6

7

8 9

12

7

JacketedG

as TrainFireboxH

eaters

113

air damper positions throughrt Numbers for the Modulat-

rd (not visible) are the same

CEI Part Number

03040060304007

Modulating Motor

The Modulating Motor controls valve andlinkage for both Gas and Fuel. The CEI Paing Motor, and the internal Resistor Boaregardless of heater size.

Description

Modulating MotorResistor BoardThe resistor board is mounted inside the modulating motor housing and must be ordered separately)

Modulating M

otor

114 Miscellaneous Parts

r

The CEI Part Numbers for these items are the same regardless of heater size.

1

2

3

4567

Item Description CEI Part Numbe

1 Strobe Light 20013122 Heat Transfer Fluid Circulating Pressure Switcha

a. The location of the Pressure Switch and Pressure Gauge vary slightly between differentsized heaters.

01020863 Heat Transfer Fluid Circulating Pressure Gaugea 04010204 Level Control 0105001

Level Control Switch (internal to Level Control)b

b. This item replaces the mercury switch (which is no longer available) on some older LevelControls.

01050025 Fire Box Thermometer 04020056 Type J Thermocouple 01031287 Fire Box Sight Glass 0401017


Section 7: Reference

Reference

116

Jacketed Heater SpecificationsFireboxHeaters

Heater Specifications

Para

met

erC

EI 1

200

CEI

180

0C

EI 2

400

CEI

360

0C

EI 4

900

CEI

630

0

BTU

Inpu

t1,

410,

000

2,11

5,00

02,

820,

000

4,23

0,00

05,

640,

000

7,30

0,00

0

BTU

Out

put

1,22

7,00

01,

840,

000

2,45

3,00

03,

680,

000

4,90

7,00

06,

351,

000

Bur

ner M

odel

CR

2-G

O-1

5C

R2-

GO

-20A

CR

2-G

O-2

0BC

R3-

GO

-20

CR

4-G

O-2

5C

R4-

GO

-30

Fuel

Usa

ge #

2 Fu

el O

il10

1520

3040

60

Fuel

Usa

ge N

atur

al G

as14

0021

0028

0042

0056

0073

00

Inco

min

g N

atur

al G

as P

ress

ure

(in W

.C.)

12-1

412

-14

14-1

616

-18

16-1

818

-20

Bur

ner B

low

er H

P3/

41

1/2

1 1/

22

35

Blo

wer

Cap

acity

(CFM

)45

263

263

296

812

9321

55

Pum

p M

odel

40-1

25/1

4050

-125

/140

50-1

25/1

4065

-160

/140

65-1

60/1

5065

-160

/150

Pum

p H

P5

7 1/

27

1/2

1520

20

Pum

p Fl

ow (G

PM

)12

017

523

535

047

059

0

Pum

p Pr

essu

re (F

t Hd

/ psi

)81

/ 35

92 /

4092

/ 40

115

/ 50

115

/ 50

138

/ 60

Ele

ctric

Loa

d (k

W)

5.2

7.6

7.6

13.6

18.1

218

Hea

t Tra

nsfe

r Flu

id C

apac

ity (G

al)

9514

516

524

027

040

0

Exp

ansi

on T

ank

Cap

acity

(Gal

)14

116

418

821

123

527

5

Pip

e S

ize

(in)

23

33

34

App

rox

Wt (

lb) l

ess

Hea

t Tra

nsfe

r Flu

id39

0046

0049

1062

0075

0088

00

117

Reference

Alarm CodesTerminals Message Meaning

Recycle L1-3

L1-40: TIME CLOCK INTERLOCK TERM L1-40

40-41: HEATER CONTROL SWITCH OFF TERMINAL 40-41

41-42: NOT USED

42-3: BC1 RELAY NOT ENERGIZED (HEAT DEMAND)

Oil Limits

44-46: REMOTE FUEL PUMP AUS CONTACT TERM 44-46

46-47: LOW FUEL OIL PRESSURE SWITCH TERM 46-47

47-48: NOT USED

48-50: NOT USED

Gas Limits

50-51: LOW GAS PRESSSURE SWITCH TERM 49-51

51-52: HIGH GAS PRESSURE SWITCH TERM 51-52

52-54: NOT USED

Non-Recycle

3-43: EXPANSION TANK LOW OIL LEVEL (SWITCH)

43-44: NOT USED

54-55: HIGH MEDIA TEMP CONTROLLER OR HMT RELAY

55-56: HIGH FLUE GAS STACK TEMP TERM 55-56

56-57: CIRCULATING PUMP AUX CONTACT TERM 56-57

57-58: LOW MEDIA(OIL) PRESSURE SW TERM 57-58

58-59: HIGH MEDIA(OIL) PRESSURE TERM 58-59

59-60: COMB BLOWER AUS CONTACT TERM 59-60

60-P: LOW COM AIR PRESSURE SWITCH TERM 60-P

118

Jacketed Safety Lockout CodesFireboxHeaters

Safety Lockout Codes

x indicates LED for item is illuminated

Lockout Message

FAN OPEN DAMPER

CLOSE DAMPER

AUTO IGN FLAME

T13 FUEL VALVE ENDSWITCH OPEN X X

M‐D LOW FIRE STARTOPEN X X

M‐D LOW FIRE STARTOPEN ‐ PTFI X X X

M‐D LOW FIRE STARTOPEN ‐ MTFI X X X X

M‐D CLOSED X X

M‐8 CLOSED X X

M‐8 HIGH PURGE CIRCUITOPEN X

FALSE FLAME‐STANDBY X X

FLAME FAIL PTFI X X X X

FLAME FAIL ‐ MTFI X X X X X

FLAME FAIL AUTO X X X

3‐P RUN INTLK OPEN ‐PREPURGE X X X

3‐P RUN INTLK OPEN ‐PURGE X X X

3‐P RUN INTLK OPEN‐PTFI X X

3‐P RUN INTLK OPEN‐MTFI X X X

3‐P RUN INTLK CLOSED‐STANDBY X

3‐P RUN INTLK OPEN‐AUTO X

FUEL VALVE STATECHANGE X

CHECK FUSE X X X

119

Reference

CHECK WIRING X X X

CHECK SCANNER X X X

CHECK PROGRAMMER X X

CHECK CHASSIS X

CHECK EXPANSIONMODULE X X X X

x indicates LED for item is illuminated

Lockout Message

FAN OPEN DAMPER

CLOSE DAMPER

AUTO IGN FLAME

120

Jacketed CONTACT INFORMATIONFireboxHeaters

CONTACT INFORMATIONCEI ENTERPRISES, INC.An Astec CompanyP.O. Box 9156Albuquerque, New Mexico, U.S.A. 87119

CEI Service (General Contact):

Phone: (800) 545-4034 or (505) 842-5556Fax: (505) 243-1422www.ceienterprises.com

Department Contact Information

Service/Parts ManagerCell: (505) 264-5259

Engineering ManagerCell: (505) 288-0323

Director of ControlsCell: (505) 263-6466

Parts RepresentativeCell: (505) 235-2789

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CEI ENTERPRISES, INC.An Astec Company

245 Woodward Road, SEAlbuquerque, New Mexico, U.S.A. 87102

CEI Firebox Heater v1.5 0813

cei jacketed firebox heater operation, service & parts manual · honeywell udc1200 modulating...

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